True North at Zimmer - - PowerPoint PPT Presentation

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True North at Zimmer - - PowerPoint PPT Presentation

Jul 11, 2023 281 likes •579 views

True North at Zimmer History of Zimmer US Orthopaedic Multinational founded in 1927: Justin O. Zimmer 1972: Acquired by

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True North at Zimmer

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History of Zimmer

US Orthopaedic Multinational founded in 1927: Justin O. Zimmer 1972: Acquired by Bristol-Myers Squibb 2001:Spin-off Zimmer from BMS and NYSE (ZMH)

Justin O. Zimmer 1884 - 1951

  • (ZMH)

2003 Acquisition of Centerpulse/Sulzer Orthopedics by Zimmer 2008 Announce Operations Expansion to Shannon, Ireland

1884 - 1951

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Zimmer Today

In the top 5 Orthopaedic Companies Globally Headquarters – Warsaw, Indiana, USA Global Sales ~$4.45 Billion >7,000 employees 13 manufacturing locations globally Celebrated 10 years on NYSE in 2011

  • Celebrated 10 years on NYSE in 2011
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$30 Billion Market Opportunity

Extremities

$1.0 Billion Global Market 15% Market Growth, full year 2009 13% ZMH Market Share #3 Market Position, full year 2009

Hips

$5.8 Billion Global Market

Dental

$3.3 Billion Global Market (5)% Market Growth, full year 2009 6% ZMH Market Share #5 Market Growth, full year 2009

Spine

$8.7 Billion Global Market 10% Market Growth, full year 2009 3% ZMH Market Share

  • for Zimmer’s human musculoskeletal system products.

$5.8 Billion Global Market 4% Market Growth, full year 2009 21% ZMH Market Share #2 Market Position, full year 2009

Knees

$6.4 Billion Global Market 5% Market Growth, full year 2009 27% ZMH Market Share #1 Market Position, full year 2009 3% ZMH Market Share #6 Market Position, full year 2009

Trauma

$4.4 Billion Global Market 6% Market Growth, full year 2009 5% ZMH Market Share #5 Market Position, full year 2009

4 Includes Bone Cement, Wound Management and Tourniquet System Products

OSP

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Shannon History

Legal Entity registered 6th Dec 2007 Site Purchased 4th Feb 2008 – Building Constructed mid 90’s – Previously occupied by Flextronics (Distribution Warehouse) Commenced Construction February 2008 Construction Works Complete September 2008

  • Construction Works Complete September 2008

First Products shipped in 2009 Achieved FDA approval 2010 2011 signified end of start up mode 2011 focus on high volume Femoral manufacturing Currently 200-220 employees

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Factory Floor – Blank Canvas

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Zimmer (ZOML) Operations Business Model

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Integrating the Business

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  • We are….

?

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Zimmer (ZOML) Operations Deployment

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Vision

  • Manufacturing will at ZOML become a strategic weapon for

Zimmer, providing the industry’s highest-quality products at the lowest cost.

  • Our ability to quickly flex capacity and respond to market changes

will set new standards and provide the commercial organization with absolute confidence in product supply, providing our sales

  • with absolute confidence in product supply, providing our sales

force with more leverage to take share.

‘Centre of Excellence’ What does that mean?

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Our Vision…

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Our Vision…

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Our Vision…

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Our Vision…

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Our Vision…

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Guiding Principles

  • People are our greatest asset
  • Safety - Everybody’s responsibility
  • Quality comes first – compliance culture
  • Always look for ways to do things better

Business Excellence ( a culture of continuous improvement)

  • Balance the books
  • Balance the books
  • Customer focus
  • Make and keep commitments
  • One set of numbers
  • Performance Management
  • Find time for important versus urgent
  • Balance short and long term views and

actions

  • Have fun !!
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CI Tools

Line-Balancing Gage R&R Anova SPC Pull Supermarkets Cellular Manf Heijunka

Shannon Manufacturing

Over Emphasis on the Tools………….be careful...

  • Mapping

Stream Value

Cause & Effect TPM Poka Yoke Standard Work 5S Visual Mgt Takt Time 1-Piece Flow SMED Metrics Ergonomics Kanban Systems OEE Jidoka Layout Analysis 6 Sigma Bench-marking

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1. Leadership Team does not actively champion the Lean-Thinking Approach 2. Lean initiatives not tied to overall Business Objectives / Goals 3. All Employees are not educated on Lean or involved in the change-process

Shannon Manufacturing

Most Common Five Lean Implementation Mistakes……….

  • 4.

No Lean Strategy / Plan is put in place 5. Over emphasis on the Lean Tools (Random Acts of Lean)

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Measure Top 10% Companies Zimmer

Customer service % 99.9 99% Yield % 99.6 95%

Why choose Lean?

Shannon Manufacturing

  • Overall Equipment Effectiveness (OEE) %

90% 45% Inventory Days on Hand 10.1 15 Annual Productivity Improvements 5-15% 10-12% Capacity used for changeovers % 0.6

April, 2008

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1.LEADERSHIP2.SCOPE

Our Drive towards Business Excellence

Shannon Manufacturing

  • 6. MEASURE

3.PEOPLE 4.PROCESS 5.TOOLS

LEAN STRATEGY

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LEADERSHIP: Training & Commitment of Site Senior Management SCOPE: Define functional areas (re lean deployment) PEOPLE: Define resources to Manage, Facilitate & Support Train all employees in Lean Principles PROCESS: Define Process for applying, reviewing and reporting Lean Activity TOOLS: Define clear toolkit that will be used to execute CI projects

Our Drive towards Business Excellence

Shannon Manufacturing

  • TOOLS:

Define clear toolkit that will be used to execute CI projects MEASURE: Agree on a set of lean-related metrics (plus calculation rationale)

“make it visual!!!”

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Key Challenges

Shannon Manufacturing

  • Source: Aberdeen Group,
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Industry - Key Challenges

Shannon Manufacturing

  • Source: Aberdeen Group,
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Factory Floor - Today

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Zimmer Operations Excellence

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ZOML Headcount

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We create the future. Enjoy the Journey!!!!!

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