Professional Profile Our Vision Our Vision Our Vision Our Vision - - PowerPoint PPT Presentation

GREELEY CONTAINMENT & REWORK INC.

www.greeley.ca

Professional Profile

Our Vision Our Vision Our Vision Our Vision

Greeley Containment and Rework Inc. Greeley Containment and Rework Inc. Greeley Containment and Rework Inc. Greeley Containment and Rework Inc. endeavours to be the benchmark by which all other Inspection, Rework and Sub Assembly companies are judged.

OUR CUSTOMERS

COMPANY OVERVIEW

Established in 1999 to provide quality inspection & rework services. Best-in-class automotive Quality Management Systems. ISO 9001:2008 & ISO/TS 16949:2009 certified since October 1999. Impeccable record of product launches. Successful in multifaceted project management. Health & Safety standards far exceed industry standards. Advanced traceability and customized software developed internally for all facets of our business.

COMPANY OVERVIEW Continued..

100% Canadian owned, non unionized, private company. 120,000sq ft. facility under 24 hour internal and external video surveillance. External secure storage available. Custom Machining and Fabricating Shop within our facility – Durmach. Established, professional management team with 10+ years average length of service. 220 Dedicated employees with 5+ years average length of service.

SERVICES WE PROVIDE

Sub Assembly & Sequencing

• Assemble 540,000 seat tracks Just-in-Time for Lear Corporation annually.

Inspection / Rework / Repair

• Inspect/Rework/Repair 2,880,000 automotive parts for suppliers annually.

Final Vehicle Inspection / Rework / Repair

• Inspect/Rework/Repair 300,000 finished vehicles for General Motors annually.
• General Motors exclusive provider of Final Vehicle Inspection, including traceability customized software for GM

Corporate.

Inventory Management, Repacking & Warehousing

• Manage 3,600,000 parts annually for Lear Corporation.

Technology, Traceability & Software Applications

• Use of scanning technology and custom software applications for all facets of our business.

ISO/TS 16949:2009

ISO/TS 16949:2009 is the International Quality Management Standard specifically written for the Automotive Industry. This elite standard results in substantial improvements in all aspects of quality, delivery and overall efficiency, far exceeding the ISO standards we also maintain.

Customized Software How it Impacts your Business

Benefits of Customized Software Solutions

• Software and, more importantly reporting, is tailor-made to your

specifications in order to best serve your business needs.

• Software is scalable and grows / evolves with your changing

business needs.

• Data can be integrated with your current software packages. All

data is held in a database file and can be exported or linked.

• Visual Manufacturing
• QuickBooks
• ADP
• Extremely frustrating when you cannot get the results you want

from your current system but know the data is available!

Final Vehicle

• Greeley has been General Motors’ exclusive provider for 9 years. In April 2016,

Greeley was awarded another 3 year contract, being our 4th consecutive tenure.

• We were responsible for the largest single rework campaign in the history of GM

Oshawa as a direct result of the faulty ignition switch issue.

• GM shut down their shipping yard while we re-cut keys for 42,666 vehicles in June 2015.
• Three week campaign, 24 hours per day, 7 days per week. An accumulated 35,253 man

hours.

• Every vehicle was quality audited both by our own teams and GM. Resulted in 100%

success.

• All data captured was reported to General Motors Detroit & Oshawa with customized reports.

Final Vehicle Cont.

• Scanning technology captures an array of information about each vehicle.
• Customized software and reporting was developed specifically for General Motors

Oshawa.

• Vehicles are checked in the yard and either released to ship or held for further

inspection, repair or rework.

• Data is uploaded to GM’s system every 15 minutes, 24 hours per day.
• GM’s on-time delivery of vehicles has increased substantially.

Job# UserID Date&Time Yard Zone Row VINnumber CSNnumber Result FailReason Shift Status 9998 JCP26 7/23/15 10:16 AM GA NGR 4 2G1WB5E33G1100010 4449437 SHIP FAIL Headlamp LH Scratch 1 R - Repaired

Seat Track Assembly

• Greeley needed to increase production by 15% to meet the needs of our

customers.

• Scanning measures scan data per employee, per day:
• Technology captures data, including date/time to the second.
• First & last scan vs start and end of shift.
• Start of breaks and return from breaks.
• Time between scans.
• We presented results to each team member, showing their performance and our

expectations going forward.

• Production increased across the company by @ 1,500 seat tracks per week.

Bulk Trim / Warehousing

• Greeley scans parts against label to ensure packing correct product into boxes.
• All boxes are scanned to specific locations on the shop floor.
• Electronic picklists are uploaded into our database directly from Lear Corporation,

showing specific requirements for the day based on GM’s requirements.

• Material is picked by location and FIFO.
• Material is shipped to Lear, and packing slip is electronically uploaded into their

system, relieving our cross dock inventory and adding to theirs.

• Streamlines process for Lear Corporation, ensuring they only receive exactly what

they need for the day’s production.

WSIB Multiple Classification Units (CU’s)

Segregated Payroll Earnings Segregated Payroll Earnings Segregated Payroll Earnings Segregated Payroll Earnings

WSIB POLICY

Policy

If the WSIB classifies an employer's operation in more than one classification unit (CU), the employer must maintain documents supporting the segregation of wage records and payroll for each CU. To do so, the documents must provide proof of the direct labour or labour time expended on each CU.

GREELEY HISTORY

In 2008, Greeley was on the verge of bankruptcy and looked for cost savings across the entire company. Payroll was $3-4 million per year and WSIB premiums averaged over $100,000. The WSIB Classification Unit, “Rework”, was based on the most technical job we were performing using hand tools and consumables. The rate was $3.03 per $100. Nevertheless, we estimated 70-80% of our work was Quality Inspection without hand tools and consumables. Research showed this rate to be only $0.38 per $100.

ESTIMATED WSIB PREMIUMS AUGUST 2008

Classification Unit Payroll Expenditure Rate Monthly WSIB Premium Annual Cost (Average) Rework $ 302,094.00 $3.03 $9,153.45 $109,841.38 Rework 25% 75,523.50 $ $3.03 $2,288.36 $27,460.34 Quality Inspection 75% 226,570.50 $ $0.36 $815.65 $9,787.85 TOTAL $37,248.19 ANNUAL SAVINGS $72,593.19

Monthly Payroll, August 2008

MULTIPLE RATE CODES APPROVED

In 2008, after months of discussion with WSIB, we obtained approval for two rate

• groups. We now have four.

Greeley was able to reconcile the entire 2007 year with the two new rate codes (legislation has since changed). Resulted in a refund of $98,635.81. Greeley’s total savings from 2007 to current is estimated at over $850,000.

Criteria for Multiple Rate Groups

WSIB generally approves multiple rate codes by how a company invoices. Different jobs within your facility may fall under different rate groups. Must allocate employee hours/direct labour cost against each specific job. Each specific job is allocated towards a rate group. Employee hours are reconciled against Payroll Final reconciliation, including salaried and auxiliary costs. Two passed audits by WSIB.

THANK YOU