Lean Six Sigma Gary Purcival Roseburg Forest Products Gary Purcival - - PowerPoint PPT Presentation

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Lean Six Sigma Gary Purcival Roseburg Forest Products Gary Purcival - - PowerPoint PPT Presentation

Nov 15, 2022 388 likes •1.16k views

Lean Six Sigma Gary Purcival Roseburg Forest Products Gary Purcival Its in the People Lean Six Sigma Blackbelt 19 years Manufacturing Experience 8 years Continuous Improvement Experience Lean and Lean Six Sigma Certified

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Lean Six Sigma

Gary Purcival Roseburg Forest Products

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Gary Purcival “It’s in the People”

  • Lean Six Sigma Blackbelt
  • 19 years Manufacturing Experience
  • 8 years Continuous Improvement

Experience

  • Lean and Lean Six Sigma Certified
  • Expertise:

– Subject matter expert in Lean and Six Sigma tools – Organizational team building – Teacher / Mentor /Coach Lean Six Sigma – Process & Machine center

  • ptimization

– Toyota Production System

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Who is Roseburg Forest Products?

  • Privately held company

that was started in 1936 by Kenneth Ford.

  • Current owner, Allyn Ford

who is also President and CEO.

  • Products include:

Lumber, Plywood (Hardwood and Softwood), Veneer, EWP, Particleboard, Melamine, Softwood Chips, and Wood pellets.

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  • Our company employees

3,000 + people.

  • We are committed to our

communities.

  • We own 650,000 acres of

timberland in Oregon and California.

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A Business Philosophy of Continuous Improvement Based on Setting Standards Aimed at Eliminating Waste Through Participation of All Employees

Lean is…

BEHAVIOR CULTURE EXPECTATIONS ACCOUNTABILITY SYSTEMS TOOLS

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  • "It is not necessary to change. Survival is not

mandatory.” W. Edwards Deming

Kiichiro Toyoda

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Why Lean & Six Sigma ?

  • Safety
  • Culture
  • Profitability
  • Survival

Our Values

  • We RESPECT our people
  • We are COMMITTED to our communities
  • We make DECISIONS for the long term
  • We practice INTEGRITY in all we say and do
  • We create a COMPETITIVE EDGE in all we do

Our Vision Roseburg Forest Products is a progressive, closely- held forest products company, building value with timberland, safe and efficient manufacturing and highly capable people. We market quality products and superior customer service at a profit to sustain growth.

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Test Today ? NO!!!

  • Kanban
  • Kaizen
  • Work Instruction Kanban
  • Value Stream Mapping
  • Value Added
  • Non – Value Added
  • Standardized Work
  • Measuring System Analysis
  • Total Productive Maintenance
  • Pareto Analysis
  • Regression Analysis
  • DMAIC Process
  • Box Plots
  • Control Charts
  • Poke Yoke
  • 5 Why’s Problem Solving
  • A3 Root Cause Analysis
  • Visual Factory
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The Secret!!

What Puts World Class Companies Ahead of The Rest ?

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Flavor of The Month ?

Trust & Teamwork TOC = Theory of Constraints QC Circles Lean Continuous Improvement

  • What is The Next flavor?
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  • Importance of Skill-Based Training

…Truly Empowering Work Groups to Think and Act For Themselves…

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Traditional vs. Progressive Skill

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  • 2 people are smarter than one
  • 3, 4, 5, 6, 7, 8 people are smarter than 2
  • For 25 years you have paid for my hands, you could have had

my mind for free!

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3M, A.B. Dick Company, Abbott Labs, Adolph Coors, Advanced Micro Devices, Aerospace

Corp, Airborne, Alcoa, Allen Bradley, Allied Signal, Ampex, Apple Computers, Applied Magnetics, ASQC, Atmel, Baxter Pharmaseal, Beatrice Foods, Bell Helicopter, Boeing, Bombardier, Borden, Bristol Meyers - Squibb, Bryn Mawr Hospital, Campbell Soup, Cellular 1, Chevron, Citicorp, City of Austin, TX, City of Dallas, TX, Clorox, Cooper Ind, Dannon, Defense Mapping Agency, Delnosa ( Delco Electronics in Mexico), Digital Equipment Corp, DTM Corp, Eastmen Kodak, Electronic Systems Center, Empak, Florida Dept. of Corrections, Ford Motor Company, GEC Marconi, General Dynamics, General Electric, Hazeltine Corp, Hewlett Packard, Holly Sugar, Honeywell, Intel, Junior Achievement, Kaiser Aluminum, Kraft General Foods, Larson & Darby, Inc, Laser Magnetic Storage, Lear Astronics, Lenox China, Litton Data Systems, Lockheed Martin, Loral, Los Alamos National labs, Martin Marietta, McDonnell Douglas, Merix, Microsoft, Morton Int'l, Motorola, NASA, Nat'l Institute of Corrections, Nat'l Institute of Standards, Nat'l Semiconductor, Natural Gas Pipeline Company of America, Northrop Corp, PACE, Parkview Hospital, Pentagon, Pharmacia, PRC, Inc, Qualified Specialists, Ramtron Corp, Rockwell Int'l, Rohm & Haas, Seagate, Society of Plastics Egineers, Solar Optical, Sony, Star Quality, Storgae Tek, Symbios Logic, Synthes, Technicomp, Tessco, Texaco, Texas Commerce Bank, Texas

  • Dept. of Transportation, Texas Instruments, Titleist, Trane, TRW, Ultratech Stepper, United

States Air Force, United States Army, United technologies, UPS, USAA, Verbatim, Walbro Automotive, Walker parking, Woodward Governor, Xerox

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  • 1987: In purchasing Toyota had 337 employees, GM had

6,000.

  • 1990: Cost of materials, tools parts, Toyota 27%, GM 70%.
  • 1990: Making 8 million cars a year, Toyota had 74,000

employees, GM had 850,000.

  • 1990: At the end of the line, at the final inspection, GM had

28 employees, Toyota had 1.

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Financial Results Page

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  • The power of working as a team
  • Feel the power of continuous

improvement

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  • In 1986 Toyota had 1.5 million employee suggestions
  • In Toyota Kentucky on average each year, there are

90,000 employee suggestions

  • In all, 95% of the suggestions are implemented!
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Glass Walls

Mini Companies

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