Your Resource for Profitable Manufacturing Growth

Transcription

1 northeastern pennsylvania industrial resource center Lean & Continuous Improvement Quality Management Systems & Industry Certification Innovation & Strategy Sustainability Workforce Development Supply Chain Development Your Resource for Profitable Manufacturing Growth

2 Our Mission NEPIRC s mission is to provide regional manufacturers with the professional services they need to maximize their profitability and achieve their growth objectives, which in turn creates regional job opportunities. northeastern pennsylvania industrial resource center

3 Implementing Business Improvements Who We Are Areas of Expertise: Lean & Continuous Improvement Quality Management Systems & Industry Certification Innovation & Strategy NEPIRC is a not-for-profit organization that has been providing world-class professional services exclusively to manufacturers throughout northeastern and northern Pennsylvania since NEPIRC works with manufacturing clients on consultative Sustainability Workforce Development Supply Chain Development engagements designed to address their unique challenges and maximize their profitability. NEPIRC s staff of professional business advisors and highly-qualified specialists design customized solutions for NEPIRC clients that enable them to adopt industry best practices, implement next generation manufacturing strategies, achieve profitable growth, successfully enter new markets and innovate new products and, ultimately, achieve profitability levels that exceed industry benchmarks. NEPIRC is one of seven Industrial Resource Centers that collectively serve all manufacturers throughout Pennsylvania and is one of 60 NIST MEP Affiliates, a national network that collectively avail regional manufacturers to over 1,600 industry professionals and a countless number of strategic partners. NEPIRC is led by a Board of Directors consisting predominantly of regional manufacturing executives and consistently strives to bring services comparable to those of marquee consulting firms such as KMPG, Deloitte, Boston Consulting, McKinsey and others to the often-overlooked small and mid-sized manufacturer market. NEPIRC s primary services focus on Continuous Improvement, Quality Management Systems & Industry Certifications, Leadership Development, Strategic Planning, Innovation Management, Technology Scouting, Supply Chain Management and Business Growth. For a complete lising of all service offerings and training opportunities please visit our website at:

4 Lean & Continuous Improvement Lean is a business system for organizing and managing operations, suppliers and customer relations. Manufacturers and other organizations use Lean principles, practices and tools to create customer value - goods and services with higher quality and fewer defects - with less human effort, less space, less capital and in less time than the traditional system of batch and queue/mass production. Lean enables organizations to grow profitably by becoming customer focused, employee focused, valuebased and resource efficient - essential in today s global economy. NEPIRC s Lean Consultants will help you: USE THE VALUE STREAM MAPPING PROCESS TO Map the flow of information and materials to help teams make immediate improvements in quality, delivery and work-flow; Use the tools of Lean, including standard work, 6S, cellular design, takt time, total productive maintenance, point-of-use storage and visual controls, to create flow in your manufacturing operations, meeting customer demands on-time, every time; and Develop a team based culture of continuous improvement across the organization ensuring long-term sustainability. Lean Strategic Alignment Lean Manufacturing Lean Manufacturing is the application of principles and tools to optimize your manufacturing operations and meet the demand of your customers while increasing your profitability. Non-value added or wasteful practices can lead to overproduction, excess inventory, defects, underutilized people, excess processing, motion and transportation. Lean Manufacturing s benefits include the reduction/elimination of waste, fewer defects, shorter lead times, increased manufacturing capacity, lower production costs, inventory reduction, increased on-time delivery and improved customer satisfaction. The evaluation of corporate strategic initiatives and the alignment of those initiatives to achieve significant performance improvements by leveraging operational excellence. For more information on NEPIRC s Lean & Continuous Improvement Services visit

5 Lean Office The same Lean principles and tools utilized in manufacturing operations can be applied to your office and administrative areas to reduce waste and eliminate non-value added activities like correction and rework, excess processing and paperwork, redundancies, waiting and searching. When you apply Lean principles and tools to your office and administrative processes, the results are better quality outcomes and processes that are efficient and responsive to your customer s needs which helps protect your profits and keep you competitive. Training Within Industry (TWI) Training Within Industry (TWI) is a set of learning disciplines and problem solving tools that enable people doing work to effectively create, improve, train and sustain standard work, while increasing productivity through problem-solving. You can use TWI methodology to teach people to: What Kind of Results Do Our Clients Have to Show for Their Work? Increased capacity up to 75% Productivity increases up to 30% annually Defects reduced by 20% per year Lead times reduced by more than 70% per year On-time delivery improved to almost 100% Inventory reductions of more than 75% Reduced floor space requirements quickly learn to do a job, identify and remove waste, resolve personnel problems successfully institute general problem-solving TWI creates a productive workplace environment where people are treated as individuals yet work together as a team, where all operators perform jobs the standard way, and where problem solving is embedded in the work Northeastern Pennsylvania Consortium for Process Excellence and Innovation The purpose of the Consortium is to provide a regional platform for organizations to share best practices and innovative approaches to address common challenges.

6 Quality Management Systems & Industry Certification Quality Management Systems are sets of standards that have been developed by the International Organization for Standardization (ISO). NEPIRC can assist you to achieve the industry quality system standards that will help you attract new customers, retain existing customers and compete in the global market. If you have a customer that requires you to be certified, or you just want to improve the quality of your manufacturing, making your company more marketable, NEPIRC Six Sigma Green Belt Six Sigma is a problem solving methodology that uses statistical tools and techniques to greatly reduce the frequency of defects and errors in products and services. It creates an environment within which defects and errors can be measured in units per million or even units per billion. As a result, Six Sigma increases customer satisfaction, reduces processing waste, compresses lead and cycle times. can help. The principles of Six Sigma are typically implemented NEPIRC s Quality Management Systems specialists can assist you in becoming registered, assist with your internal quality auditing or train your internal quality auditors in the following quality standards: ISO 9001 General Quality Standard AS 9100 Aerospace Standard TS Automotive Standard through the performance of targeted improvement projects that apply the proven Define, Measure, Analyze, Improve and Control (DMAIC) approach to specific production or administrative processes. Most projects can be performed by a qualified Six Sigma Green Belt, although a Six Sigma Black Belt may be needed for larger projects. ISO Laboratory Standard ISO Environmental Management Standard OHSAS Health & Safety Standard API Q1 Petroleum & Natural Gas When you make the strategic decision to become registered to a quality standard, NEPIRC assigns you a Quality Systems Specialist to work at your facility with you and your team, preparing you for the registration audit. This ensures you receive a comprehensive snapshot of the things you re doing right - as well as constructive ways to improve. And you ll have it all documented for future use. For more information on NEPIRC s Lean & Continuous Improvement Services visit

7 Our 5-day training course is designed to provide participants with knowledge of Six Sigma concepts, roles and implementation approaches sufficient to enable them to identify Six Sigma implementation opportunities and conduct Six Sigma projects with limited involvement of a Six Sigma Black Belt. Participants learn how to launch a successful Six Sigma project, apply the DMAIC approach to the identified process, quantify the final benefits of the project and report project outcomes to their peers and supervisors. Ideally, each graduate will be able to perform small Six Sigma projects on their own. API (American Petroleum Institute) Q1 Quality Management System NEPIRC can help your company obtain this Quality Management System Certification from America s only National Trade Association in the Oil and Natural Gas Industry. This Certification allows all Organizations including Manufacturers, Distributors, and Service Companies, who meet the Quality specifications, to provide products and services in the Oil and Natural Gas Industries worldwide. The API Q1 Specification requires: We ve been using nepirc s iso and ohsas audit services for several years now, and have been consistently delighted with the service they provide. Nepirc is a local resource that is very valuable to the manufacturing community and provides services we would not be able to find elsewhere. - Fairchild Semiconductor Implemented control features to assure quality assurance, supported by ample quality procedures and records Focus on the Customer, not just customer satisfaction. Continual Improvement and Corrective/preventive action. API Monogram Program that allows a Valid API License holder the opportunity to apply the API Logo to the products that fall within the scope of their approved program. This program is based on ISO 9001, and includes additions to that standard. NEPIRC has a 100% SUCCESS RATE in having its Clients receive ISO 9001 Registration.

8 Innovation & Strategy NEW MARKETS NEW PRODUCTS NEPIRC can bring to your business what it takes NEW PROCESSES SEIZE YOUR GROWTH & INNOVATION OPPORTUNITIES NEW BUSINESS MODELS NEW SERVICES to innovate more successfully with less cost and reduced risk. Using proven systems and tools, our certified, experienced specialists, will help your organization seize opportunities through a diverse portfolio of professional services. Competitiveness Review An objective assessment of your business capabilities and systems, benchmarked against others in your Most business leaders agree Innovation is the key to profitable and sustainable growth. The challenges lie in not what to do, but how to do it quicker, with less cost and reduced risk. industry, may be exactly what you and your management team needs to develop a roadmap for success. Your trusted NEPIRC Business Advisor will help you determine if this is step one for your organization. If you are like most businesses, you have not sat idle as competitive forces and product commoditization increased negatively impacting markets and margins. Perhaps you have enhanced your service offerings, introduced new or improved products, and/or entered new markets. Some ideas have worked while others have not. Some ideas took too long and as a result opportunities were lost, while you wish some other ideas that took time and money would have been eliminated earlier. While these challenges can cause businesses today to be more cautious this is not the time to slow down or stop innovation. In fact, now is the best time to innovate. Many of the greatest innovations in history have occurred during times of economic slowdown. Strategy Development and Implementation No one strategy or tactical action will get the job done. Many factors and critical inputs can and should impact the strategies and actions that will guide your business. NEPIRC will help you to select inputs such as; voice of customer survey, market research and competitive intelligence that will best support your strategic development process and enhance the output of the initiative. Our business facilitators will engage your management team and challenge your thinking. Once the plan is developed, a NEPIRC Specialist will support the implementation process to help you achieve your vision and goals. For more information on NEPIRC s Innovation & Strategy Services visit

9 Idea Generation Our innovation methodology is based on a proven system to stimulate ideas for new products, services, processes and business models to quickly evaluate which ones have the highest probability of success using a set of proven tools and business simulators. Through this process your organization will develop a pipeline of ideas for profitable growth. Innovation Engineering Management System The Innovation Engineering Management System (IEMS) is a proven system of tools developed through scientific inquiry grounded in hard data and proven reliable in real world applications. Over the past 25 years, these tools were only available to big companies Nike, Hewlett Packard, Walt Disney, Proctor & Gamble, etc. Now these tools are available to all businesses through NEPIRC. Marketing How effective is your marketing, messaging and value propositions? The reality is that emphasizing your great quality and excellent service won t get it done. Market Research, Competitive Intelligence, Voice of Customer Survey, Branding and Messaging Development are just some of the ways that NEPIRC can help you stay in front of the competition, differentiate your offerings, and create interest in your products and services. NEPIRC can help you to identify the critical needs of your targeted customers and how to effectively communicate your capabilities and value in your marketing messages and value propositions. New Product Development Innovation means making meaningful change to improve an organization s products, services, programs, processes, operations and business model to create new value for the organizarion s stockholders. Building upon Idea Generation and implementing IEMS described above, your organization will be better positioned to launch new products. However, consistent results will only occur when a system Baldrige Criteria for innovation and culture of innovation is in place that can develop the best ideas, eliminates the bad ideas sooner, and can commercialize products quickly and cost effectively.

10 Innovation & Strategy (continued) Sales The sales revenue engine of your company has many components and parts that impact performance. All components are interdependent on each other and need to be in alignment in order to achieve maximum performance. For these reasons, NEPIRC begins with a thorough assessment of your capabilities and constraints to generate sales revenues. Conducted by sales growth experts, this independent, objective assessment will become the roadmap for increased revenues and profits. If you re considering sales training, hiring new reps, or changing your sales channels to increase sales STOP. Let us help you to identify and prioritize what steps to take and how best to implement the actions that will get you the results you desire sooner and lower cost. companies that have participated in these same services and have realized the following impacts to their businesses: Average increase sales of $170,000 Average cost savings of $34,000 Average savings of 120 hours of labor time CoreValue CoreValue is a program offered for business owners to understand, quantify, and improve their business. Delivered via an engaging web app, CoreValue provides a framework for the business owner to quickly identify and measure the value of their business, the drivers of that value, what s holding them back, and how to make improvements. Exporting Do you believe your products have international sales potential, but don t know where to begin? Have you received international inquires, but haven t fully capitalized on them to generate significant sales growth? Would you like to have a proactive approach to expand your international sales? FINANCIAL ASSISTANCE NEPIRC actively aligns with existing business and grant programs to enable manufacturers to reduce the costs of their improvements. Whether its project subsidies, customized job training grants or project financing, NEPIRC s financial initiatives are an additional valueadded resource to ensure that small and mid-sized manufacturers have the tools they need to grow in NEPIRC can help you to gain more clarity on your international sales growth opportunities and help accelerate your exporting success. Our specialists will deploy a systematic process consisting of proven tools and templates to help you to develop a simple, actionable international growth plan. We will connect you with reputable international business experts who will help you to navigate the export process saving you time and money. Now is the time to join other northeastern Pennsylvania. NEPIRC administers a U.S. Department of Commerce Economic Development Administration Revolving Loan Program as well as our own internal Revolving Loan Program established by our Board of Directors. Both loan programs can provide your business with term financing for machinery, equipment or other assets needed to expand your business at rates BELOW the prevailing prime lending rate. For more information on NEPIRC s Innovation & Strategy Services visit

11 Sustainability Green is smart business - today and for the future. Green Manufacturing is part of a continuous improvement strategy helping manufacturers improve their productivity, profitability and competitiveness. Green seamlessly integrates with Lean Manufacturing practices to optimize processes resulting in an improved environment, worker health and safety, and energy performance. Generating waste costs money. You pay for it three times over - when you buy it, when you process it and when you dispose of it. NEPIRC s Green Manufacturing program will show you how improved environmental performance and increased profitability go hand in hand. Using environmental best practices to eliminate the other wastes is the next logical step in the Lean transformation. The benefits of Green Manufacturing include: Reduced scrap and rework Reduced hazardous wastes Improved environmental performance Prevention of compliance and liability costs Reduced quantity of raw materials, resources and energy required to realize your product. NEPIRC s Green Manufacturing experts can help you eliminate waste at its source, meet regulatory requirements and maximize the effective use of your resources. Green Manufacturing Solutions include: Green Generalist Training Waste Stream Mapping Material and resource selection and optimization Process improvements Energy conservation and management Water conservation Assessments and audits Regulatory compliance ISO Environmental Management System (EMS) OHSAS Occupational Health and Safety Management System ISO Energy Management For more information on NEPIRC s Sustainability visit

12 Workforce Development Leadership Development Essentials Leadership Development Essentials is a series of ten (10), four-hour sessions that are highly interactive and utilize a variety of instructional techniques including: lectures, work sessions, group discussions, role playing, in the global economy, your employees need to be customer-focused and operate as a highly effective team while management needs to provide a compelling vision and work environment, focusing efforts to create a stronger company. video, self-assessments, and practical applications. Participants are encouraged to bring real life issues to each session to facilitate on-the-job application of the skills learned. NEPIRC provides solutions that enable organizations to maximize employee performance to meet constantly changing business needs. Our goal is to assist you in identifying opportunities and hurdles and the creation These sessions are geared to CEO s, VP s, District Managers, Directors, Supervisors, First time supervisors, front-line and mid-level supervisors, Foremen, Coordinators, and Team Leaders responsible for directing the workforce. Participants will understand how to effectively manage today s workforce in the day to day operation of the organization. Corporate Culture Services Company culture greatly influences daily productivity of manageable solutions that lead to improvements in your overall operational effectiveness. We utilize a holistic approach to implementation that leads to positive, lasting change. Public Training Sessions NEPIRC can provide you with the tools you need for positive change and growth. We offer comprehensive training programs designed to provide real-world solutions for your toughest business challenges. and continuous improvement. In order to succeed For more information on NEPIRC s Workforce Development Services visit

13 When you commit to training with NEPIRC, you ll receive top-notch instruction from experienced professionals at prices that won t break your budget. Classes are guaranteed to ensure excellence within your organization, and provide easy-to-implement solutions to keep your business running smoothly. NEPIRC will help you to create training that impacts your bottom line and maximizes ROI of your staff development. All of our programs can be designed around your requirements and are customized to: Impact employee job performance Focus on priority business challenges Reinforce processes, procedures and best practices Use actual organization projects in course curriculum Maximize learning convenience through flexible scheduling All training is available to be done onsite. Youth Apprentice Program NEPIRC has been a valuable training and consulting resource for our company. Our Six Sigma Green Belt training was very successful, and we were able to build upon it with NEPIRC-provided Statistical Process Control and Leadership Development training, both of which added to our employee skill sets and generated additional positive returns for us. - Ward Manufacturing High school students are invited to participate in this on-the-job program that gives them worksite experience and a day s wage, while in high school. Selected students report to work at the business one or two days a week. A mentor oversees their work. A training plan is developed to help the students track their progress. Students observe and practice the technical skills they need as well as the communications and team building skills that help a company succeed. Designed as a program, each student is encouraged to continue their work experiences after high school, as they pursue their education at a college or technical school.

14 Supply Chain Development Next Generation Rail Supply Chain Department of Defense (DOD) and Department of Energy (DOE) encouraged the Department of Transportation (DOT) to form a partnership to leverage the nationwide MEP network to cultivate a domestic supply base to support next generation rail transportation in the U.S. The focus of the partnership is to attract and identify U.S. companies that can manufacture components needed for the next generation rail system. DOT introduced the next generation rail procurement Buy American Supplier Scouting Buy American Supplier Scouting is a collaboration of federal agencies and MEP to scout for U.S. manufacturing capabilities to support the Buy American Provisions of federal funding programs, including the American Reinvestment and Recovery Act (ARRA). The provision generally states that, subject to certain exceptions, when appropriated funds purchase manufactured goods for use in certain federally-funded projects, those goods must be manufactured in the U.S. opportunities in 2012 and has set the goal of 100 percent domestic content in the manufacture of nextgeneration rail equipment. The program is designed to bring business opportunities to small U.S. manufacturers with specific capabilities and capacities. In response to the supply chain needs Opportunities exist for Small Manufacturers in Next Generation Rail Supply Chain. More than 30 locomotive and rail car manufacturers, both domestic and foreign, have committed to establish or expand their base of operations in the United States to build America s next of federal agency and original equipment manufacturer (OEM) partners, MEP leverages its vast knowledge of local manufacturer capabilities to identify and prequalify supplier capabilities and capacities, and provide assistance to suppliers as needed. generation high-speed rail lines. Collaborating with federal agencies, MEP developed The Next Generation Rail Supply Chain Connectivity efforts will help connect small manufacturers with those committed locomotive and rail car manufacturers and will give them the opportunity to see how they could be part of the domestic supply chain for next generation rail. processes that leverage its network of manufacturing specialists in all 50 states and Puerto Rico to explore the U.S. manufacturing landscape in search of certain American made products needed for projects that are subject to Buy American provisions. When project awardees have difficulty satisfying the Buy American NIST MEP will help to ensure manufacturers meet the U.S. Department of Transportation s Buy American and Buy American standards connecting U.S. manufacturers and suppliers for work on intermodal transportation in the Unites States and in the process to help create jobs. provisions typically because they can t find American companies to make the products they need they submit waiver requests to their federal funding agency. MEP s role is reviewing the requested waivered items, and finding suitable U.S. made products. For more information on NEPIRC s Supply Chain Services visit

15 The Website keepitmadeinnepa.com showcases the vast array of products and Keep It Made In Northeastern PA Keep It Made In Northeastern PA is an initiative of NEPIRC to recognize manufacturers who produce products within the region and employ more than 41,000 people. NEPIRC would like to recognize the contributions of manufacturers in this region and feature those companies that have contributed to the growth of the economy, are customer focused and forward thinking, strive to create jobs, continuously improving their productivity, and desire to grow and compete both locally and globally. the companies that are manufacturing them. The site provides resources both to manufacturers and the general public.

16 NEPIRC Service Area TIOGA SUSQUEHANNA BRADFORD WAYNE SULLIVAN WYOMING LACKAWANNA PIKE LUZERNE COLUMBIA 75 Young Street Hanover Industrial Estates Hanover Township, PA northeastern pennsylvania industrial resource center Phone: Fax: NEPIRC is funded in part by the PA Department of Community & Economic Development and the U.S. Department of Commerce National Institute of Standards & Technology. MONROE ISO9001:2008 DEKRA CERTIFIED