MESA P2E Conference

Tuesday, September 23 - Presentation Descriptions*

In the Strategic Initiatives Track attendees will learn best practices and guidance that detail how plant-wide information systems support five key strategic corporate initiatives – lean manufacturing, quality and regulatory compliance, product lifecycle management, real-time enterprise, and asset performance management.

The Foundations Track provides the basics for helping you realize the value of plant systems. Attendees will be able to select session content based on their experience level or on their deployment lifecycle – providing individuals with the opportunity to customize their learning experience.

9:15 – 10:00 am
Innovation to the Core
Peter Skarzynski, Managing Director, Strategos

If you are like most business leaders, innovation now tops your corporate agenda. However, despite all the talk and excitement about its importance, managers are frustrated by the absence of a practical blueprint for building innovation capabilities in a systematic way that fuels sustained growth while addressing operational issues. Peter Skarzynaki will help you change that in this interactive presentation filled with real world examples and practical insights. You will also learn how to engage front-line employees in the innovation process, leverage IT to enable innovation across the enterprise, and balance the tension between day-to-day operations and innovation.

10:30 – 11:15 am (Foundation Track)
Creating a Holistic Performance Program: Metrics for Production AND Distribution Effectiveness
Julie Fraser, Principal Industry Analyst – Cambashi
Dr. Karl B. Manrodt, Associate Professor in the Department of Management, Marketing & Logistics – Georgia Southern University

Plants and warehouses must work together to achieve business performance improvements in order fulfillment, inventory, productivity, quality and compliance, flexibility, and mass customization. MESA’s Metrics Working Group co-chair, Julie Fraser, will present joint and conflicting metrics with the Warehousing Education and Research Council (WERC) researcher, Karl Manrodt. This work is also supported by the Materials Handling Industry of America (MHIA) Order Fulfillment Council (OFC) and Supply Chain Execution (SCE) groups. Attendees will learn how to find joint ground with warehouse peers, build a business case, and get a sneak preview into the 2009 benchmark study.

10:30 – 11:15 am (Strategic Track)
One Enterprise Quality – Digitize Your Quality Management System
Sharad Nigam, Associate Consultant, Manufacturing Center of Excellence – Tata Consultancy Services Limited
Sreenivasa Chakravarti, Automotive Lead, Manufacturing Center of Excellence – Tata Consultancy Services Limited
John Phillips, Director, Standards Integration – Cummings Inc.

A process model that integrates the quality functions across the value chain and quality perspectives from ‘board room to shop floor’ holds the key to a ‘One Enterprise Quality’ platform. Architected around service-oriented principles, this solution would enable different stakeholders to leverage a ‘single source of truth’ and work proactively towards a common corporate quality objective. A powerful ‘digitized enterprise quality system’ with measurement metrics, embedded with the toolkit to manage quality projects, reflecting the flavor of the enterprise QOS, and with the capability for knowledge and content management transforms quality into a stakeholder focused process.

10:30 – 11:45 am (SOA in Manufacturing Track)
Panel: SOA in Manufacturing
Moderators: Tim Thomasma, Managing Enterprise Architect – Capgemini
David Noller, Manufacturing Solutions Development – IBM
Panelists: Mike Brooks, Venture Executive – Chevron Technology Ventures; Charlie Gifford, Chief Manufacturing Consultant, 21st Century Manufacturing Solutions, LLC; Bryan Zigler, Product Lifecycle Management Engineer Product Definition Technology – Boeing Phantom Works

Industry is abuzz with talk about Services Oriented Architecture (SOA) and the promise that it holds. Join end users along with the authors of MESA’s new “SOA in Manufacturing Guidebook” for a discussion on best practices and the value of implementing SOA in manufacturing. Panelists will address these issues and more:
• How do you create a business case for SOA?
• What are the business benefits?
• What are the business enablers?
• What challenges will you face in moving from current state to SOA?

11:30 – 12:15 pm (Foundation Track)
Metrics for Diagnostic Purposes
Steven Kaplan, Global MES Administrator – Murata Power Solutions

In this new millennium of global diversity and competition, manufactures are pursuing excellence through a variety of proven methodologies. We strive for a completive edge through on-time delivery, quality and customer satisfaction. We struggle to be the first to market, then from the financial side, look for strong margins and profitability. The questions that keep emerging are; Are we there yet? How did we get here? Where are we going? The answers lay in a company’s metrics. Metrics do matter, but which metrics matter and what do we do with all this data. Where did all this data come from and what are we going to do with it. Is it all necessary?

11:30 am – 12:15 pm (Strategic Track)
Product Lifecycle Quality: A Framework within Production Lifecycle Management (PLM) for Achieving Product Lifecycle Quality
Dr. Michael Grieves, Director, PLM Institute – Oakland University

The issue of quality is an extremely important one in today’s environment, however, the term “quality” is an ambiguous one that means different things to different people depending on their phase of involvement with a product. Product Lifecycle Management (PLM) with its holistic view of a product from birth to death requires an equally encompassing view of quality. Dr. Grieves will discuss Product Lifecycle Quality (PLQ), and how it defines an overall view of product quality. Special focus will be on the role of manufacturing systems in creating both the physical and virtual products necessary for truly quality products.

11:30 am – 12:15 pm (SOA in Manufacturing Track)
Excellence in Work Processes
Mike Brooks, Venture Executive – Chevron Technology Ventures

Supply chain pressures vary, domestic energy costs are soaring, but all manufacturers strive to produce more for less – regardless of product. Buy the right raw materials at the right price and use the right equipment to deliver the right slate of finished goods, while minimizing waste and optimizing production. Not so easy, is it? The big ERP spend spurred by Y2K did not pay out large promises, mainly because those initiatives ignored manufacturing! Even MES provided only slight relief, and newer “techniques” such as “order-to-cash” and “manufacturing as a service” still deal with manufacturing as a black-box. Such treatment ignores the importance of manufacturing as a critical fully integrated element of the entire supply chain where a great deal of value can be created...or lost. How does manufacturing improve where detached departments such as maintenance, planning, operations and quality, own isolated functions that dutifully fail to align with the overarching value chain goals?

1:45 – 2:30 pm (Foundation Track)
Real-Time Interactive Work Instructions
Marlene Eeg, President – Tempo Resources Inc.
Steven Kaylor, VP Operations – Sechan Electronics, Inc.

Operational Challenges: Need current, task-specific instructions with photos, illustrations and easy-to-understand instructions for Manufacturing, Quality, Maintenance and Training to increase effectiveness and profitability.

Engineering Challenges: Using design documents or office tools to produce limited instructions for Manufacturing and Quality Operations are often ineffective resulting in excess labor costs, version control issues, and inability to create standard process documents for operators and Lean, ISO and regulatory compliance requirements.

This presentation is NOT about managing static documents or linking documents to operator workstations. A manufacturer’s scenario will be presented by Sechan Electronics Inc., who selected a new, database-driven solution to replace their paper instructions to create a real-time, interactive deployment of paperless Work Instructions.

1:45 – 2:30 pm (Strategic Track)
Enterprise Asset Performance Management
Fayez Kharbat, Engineering Specialist – Saudi Aramco

While Asset Performance Management (APM) has been an interesting topic among global companies, the demands of a cultural change and technology transformation, compounded with the time to realize benefits, often prevent the visibility of bottom line financial gains. APM enables companies to put strategies in place for improving equipment performance and operational efficiency, reducing operational risk and maintenance cost, managing compliance and ensuring that your reliability processes are aligned with your business goals. Unplanned downtime reduction, increasing assets lifecycle, and improving assets performance are immediate gains because of a successful deployment of an APM solution. This presentation will address what it takes to have a successful implementation and what strategy should be in place.

1:45 – 2:30 pm (SOA in Manufacturing Track)
A Lean SOA Approach Enables “Build Anywhere” at Boeing
Bryan Zigler, Product Lifecycle Management Engineer Product Definition Technology – Boeing Phantom Works

Many manufacturing companies have adopted “Lean manufacturing” concepts as a methodology to guide process improvement. While much of the traditional focus of Lean is on the product being developed, many of the Lean principals are applicable to the information technology systems that support the manufacturing environment.

Service Oriented Architecture (SOA) has become a dominate topic of discussion in information technology as the standards in Business process modeling, web service and XML have been adopted. Many of the concepts behind SOA align with lean Concepts. One example is the lean concept of standard work, which is similar in to exposing IT functionality as a service. Just as standard work enables flexibility, so does having IT functionality exposed as services.

2:45 – 3:30 pm (Foundation Track)
Case Studies on the Use of Software to Implement Lean in High-Mix Manufacturing Industries
Tom Knight, Founder and Chief Strategy Officer – Invistics

What is the role for software in lean manufacturing, and how have companies successfully utilized software to implement lean? This talk will present case studies from several high-mix industries, including chemicals, food & beverage, and electronics companies, and illustrate how these companies have used Lean Software to reduce inventories and cycle times by 50% or more while improving customer service and throughput.

2:45 – 3:30 pm (Strategic Track)
Applying Lean Six Sigma and MES to Improve Yields and Reduce COGS
John Rassieur, Systems (GIO/MES) Horizontal Leader, Global Business Services, Globally Integrated Operations/Manufacturing Execution – IBM

A Tier 1 wheel manufacturer case study will be discussed to show how four steps were used to improve production yields and reduce Costs of Goods Sold were utilized and may be applied:

• Lean Manufacturing was used to identify waste from the manufacturing process and identify key manufacturing attributes to control.
• MES is being planned to create a systemic mechanism that creates a “cause and effect” relationship for Continuous Process Improvement (CPI).
• Six Sigma methods are planned to reduce process variability and incorporate process improvements back into the MES.
• Event Driven Response System allows a manufacturing enterprise to react and plan on a real time basis to dynamic business conditions, optimizing the orchestration of manufacturing activities. It is aided by information received from elements 1-3, creating an integrated solution.

2:45 – 3:30 pm (SOA in Manufacturing Track)
Interoperability Compliance completes the SOA Business Case
Charlie Gifford, Chief Manufacturing Consultant - 21st Century Manufacturing Solutions LLC
Randy Okubo, Technical Manager - 3M IT Supply Chain Solution Center

Across the industry, the SOA vision enables interoperability between enterprise, supply chain, plant operations systems and other manufacturing/production applications. For the SOA vision to be successful, industrial interoperability standards, need to provide manufacturers Lean IT systems through common definitions of data and processes. Adaptable global manufacturing is only able to be accomplished through adaptive interoperability of business and manufacturing processes. When industrial systems are truly configurable to produce configurable business process, interfaces, reports, and metrics, a key requirement for adaptive manufacturing and production processes for 21st Century global markets has been accomplished.

4:00 – 4:45 pm (Foundation Track)
Driving Down Underlying Cost of Production in Less Than a Year in a Multi-plant Business through “Human Capital”
George Jurkovich, Senior Vice President of Operations – Bay Valley Foods, LLC
Mark Sutcliffe, General Manager – CDC Software’s CDC Factory

As a leading provider of private label goods in North America, Treehouse Foods, a 10 plant business unit of Bay Valley Foods, was rapidly growing through acquisitions. They realized they needed an information framework capable of managing the effectiveness and performance of their existing plants. They also needed a system which also would enable the swift integration of new acquisitions into their business, the ability to capitalize on consistent performance metrics, and support of continuous improvement, OEE measurement and daily best operating practices (many based on Lean manufacturing techniques). This presentation will focus on the journey in implementing a Manufacturing Operations Management (MOM) system, and delivering systematic reductions in the underlying cost-of-production, in under six-months per plant.

4:00 – 4:45 pm (Strategic Track)
Applying Process Excellence: Challenges in the Blood Supply Chain
Chetan Makam, Director, Office of Business Process Excellence – Haemonetics

The need for blood components to help patients with surgeries, cancer treatments and trauma continues to put pressure on blood centers to collect the right product from the right donor at the right time.

Blood centers are faced with the challenges of: 1) Donor shortages, 2) Increased regulatory compliance, 3) A sustainable economic model and are wondering how they can best meet these challenges.

Applying Lean and Six-Sigma processes enable blood centers to convert chaos and complexity into a structured process driven approach that delivers sustainable response to demand without compromising safety, quality and performance.

*Presenters and topics subject to change.