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2012 Employee Town Hall CRT Report Out

2012 Employee Town Hall CRT Report Out. Production Metrics Safety Strategy Deployment Value Stream Projects Lean Efforts Plant upgrades. Ink Production . Dispersion- Manufacturing. YTD – 12.4 Million Pounds 37% increase over last year. 3 Roll Mill Yellow into storage tank

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2012 Employee Town Hall CRT Report Out

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  1. 2012 Employee Town Hall CRT Report Out • Production Metrics • Safety • Strategy Deployment • Value Stream Projects • Lean Efforts • Plant upgrades

  2. Ink Production

  3. Dispersion- Manufacturing • YTD – 12.4 Million Pounds • 37% increase over last year. • 3 Roll Mill Yellow into storage tank • 8.1 Million pounds of dispersion vehicle

  4. Varnish Manufacturing • 18% Increase YTD over last year. • 29% increase in structured varnish. • 16.5% decrease in non structured varnish • Significant shift to retail ink = more clay base, more structured varnish. • Retail ink uses less manufactured varnish overall.

  5. PMS, Fountain Solution, and MISC.

  6. Safety Measures • First Quarter 2012 Dart rate 3.37 • Dart rate is important for tracking incidents and injuries more importantly dollars and cents make the biggest difference. (Days Away, Restrictions, and Transfers) • CRT Work Comp 2011 $5,134.58 • CRT Work Comp YTD 2012 $33,264.00 • Work safe.. we’re trending in the wrong direction • Quad would need $1,000,000 in sales to make up the YTD Work Comp, just to break even.

  7. Strategy Deployment Value Stream Mapping Quad Lean Q “use the collective thinking power of all employees to make their organization the best in its field." -Professor Kaoru Ishikawa

  8. Quad/Graphics' Mission Statement • We are a value driven company committed to our clients, employee owners, shareholders, communities and the environment. • As the industry leader, we take print to a higher level through service, quality and technological innovation. • We will grow profitability as the high value, low-cost producer.

  9. Strategy Deployment • Focus on a shared goal • Communicate that goal to all leaders • Involve all leaders in the planning to achieve that goal. • Hold each other accountable to achieve their part of the plan

  10. Strategy Deployment • Long Term Goals • Secure Raw Materials at the highest quality, lowest price. (RFP) • Digital Inks – Ink jet • Mexico and South America will utilize CRT Products • CTO – TOR trade for finished Resin • Adhesives • Quick Hits (now) • Wax Manufacturing • Clay base Manufacturing • 3 Roll Mill Yellow • Remove toner from Black Ink • Fountain Solution • OPV • National GEO Inks

  11. Combined Wax Manufacturing $2.9 Million Savings • CapX: $1.2 Million • Fast Track Wax Production: April 1st-$506,000 Savings • Full Scale Production Using Molten Wax Storage Process System Original Completion Date: July 1st, 2012

  12. Dry Pigment Volume Capitalization $800k Savings (end of 2nd quarter) • Ongoing Quarterly Project • $300k 1st Quarter Savings • $500k 2nd Quarter Savings (increased savings due to new supplier) • Minus Carbon Black Increase Due to Natural Gas and Oil Market

  13. Fountain Solution Scale Up • Projected Completion Date: July 1st, 2012 • Original Completion Date: July 1st, 2012 • CapX: $419k – On Target • Initial Fountain Solution Production Adds Additional $95,000 Savings • 10 Plants Using Fountain Solution 100% • Some reformulations • 2804 no longer • 2805 work horse product • 2801 Manrolands - Hartford

  14. Manufacture Clay Base $436k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 13th, 2012 • CapX: $228k – On Target • Full Scale Production Delayed 2 Weeks • Clay Conveying System Needs Additional Work Due to Complexity of Clay Particle Size (must be correct) • Potential for Additional Savings for Using a Less Refined Clay

  15. Manufacture National Geographic Cover Inks $185k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 1st, 2012 • Preliminary testing was good, need 1 additional test to move forward. • Additional Savings Due to Saratoga Also Using Ink Series

  16. Manufacture Overprint Varnish $97k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 1st, 2012 • CapX: $25k – On Target • Raw Materials for Testing are Procured • Overprint Varnish is Manufactured • Tested in Sussex – slight formulation change needed • Additional testing

  17. Remove Alkali Blue $1 Million Savings • Original Completion Date: July 1st, 2012 • Formula is Created and Ready for Release to Production • Currently There Are No Standards for Plate Curves (Bob Hallam is Working on) – Test complete 6/07

  18. Supply Sheetfed Ink $1 Million Savings • Projected Completion Date: July 1st, 2012 • Successful Ink and Fountain Solution Test in Dubuque • Currently Testing of Different Packaging • When Additional Sheetfed Ink is Rolled Out, Fountain Solution Will be Included • UPDATE – New Berlin, Dubuque, Burlington, and Waukee successfully running this ink 6/8

  19. Yellow 3 Roll Mill $700k Savings • Original Completion Date: July 1st, 2012 • Projected Completion Date: July 30th, 2012 • CapX: $200k – On Target • Purchased Used Mill from Germany • Will Arrive in New Jersey Week of March 12th • Buhler to Refurbish to ANSI Standards and Deliver to CR\T by May 15th, 2012 – Last week of June • All Material Needed for Base at CR/T • Project Ahead of Schedule – 4 weeks behind

  20. Value Stream Event and Planner • Production road map for the improvement cycle.

  21. Improvement Metrics

  22. Lean Events YTD • Value Stream Mapping Event – 1/20/2012 • Review Standard Work (Ink) – 2/1 – 3/1 • Citdel Process Detail Event – 2/20/2012 • Operator Balance Event – 4/05/2012 • RCA Class – 5/10/2012 • 6-S Compound Pit – 5/14/2012 • Etch Standard Work – 5/25, 5/30 • RCA Class – 6/5/2012 • 6-S East Docks – 6/25/2012

  23. Building upgrades • 200 HP Boiler being installed late summer. • New AC Unit on Building one being installed early July. • Last 24 months Quads invested over $4 Million at CRT Hartford.

  24. Any Questions?

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