Seventieth Meeting of the Advanced Manfacturing Forum
Best Practices in Lean and Sustainable Manufacturing
October 13-14, 2011
Toftrees Golf Resort & Conference Center
Lean and Sustainability at Shearer's "Plant of the Year" Facility and Beyond
Scott Smith, President
Shearer's Foods, Brewster, OH
Founded in Canton, Ohio by the Shearer family almost 40 years ago as a single-truck distribution business, the company now manufactures over 200 million pounds of potato chips and other salty snacks each year from its five plants across the country. Shearer's recently build the first US Green Building Council LEED ® (Leadership in Energy and Environmental Design) Platinum certified food manufacturing plant. The plant and company have recently been recognized as "Plant of the Year" and "Manufacturer of the Year" by numerous publications and organizations. This presentation will discuss the driving forces behind Shearer's commitment to sustainability, the story of this plant and the successes achieved, as well as the broader impacts of sustainability on all aspects of the business.
Shearer's Foods Executive Summary (kB .pdf) -- coming soon
Pfizer's 93% Renewable Energy Manufacturing Facility
Rob Gergen, Senior Director, Network Performance
Pfizer Global Manufacturing, Collegeville, PA
Michael Becker, PGE Director and Engineering Leader
Primary Care/Oncology OpU, Freiburg, Germany
Pfizer is a worldwide biopharmaceutical company committed to applying science and its global resources to improving health and well-being at every stage of life. In pursuit of its company's vision and mission, the Pfizer Global Supply (PGS) Manufacturing division is on a journey toward operational excellence and has consolidated many improvement programs into a single organizational construct called Network Performance, where actions are driven by a balanced scorecard of metrics, and chief among these is its commitment to environmental sustainability. Pfizer's Freiburg manufacturing site has been a corporate leader in the implementation of CO2-reduction projects including wood-pellet combined heat and power (CHP) and geo-thermal energy applications. In 2011, Freiburg surpassed the goal of 93% of energy consumption from renewable energy sources with the objective of becoming a CO2-neutral facility. This will be discussed as part of this presentation.
Pfizer's Executive Summary (kB .pdf) -- coming soon
What Makes America's "Best Plant" a Winner
Greg Yezback, Plant Manager
American Axle and Manufacturing, Three Rivers, MI
AAM's Three Rivers Manufacturing Facility (TRMF) is a national leader in effectively implementing lean manufacturing. It achieved this by developing and implementing three key lean manufacturing tools in collaboration with all associates. The first tool is standardized work in which the most efficient and repeatable way to perform tasks is developed, introduced, and monitored rigorously. The second tool is value-stream management, which allows understanding and reduction of product-related materials and information flows throughout a plant. The third tool is the A3 Problem Solving Process, which is used to systematically identify and solve the root causes of problems. As shown at TRMF, when integrated into a complete program, this triad of tools has a powerful impact on plant performance when the program is led from the top and involves and recognizes associate contributions.
American Axle and Manufacturing's Executive Summary (kB .pdf) -- coming soon
SKF and Sustainability... Going Beyond Zero
C.W. McGlocklin, Director of Environmental Affairs
SKF USA Inc., Lansdale, PA
SKF Group is the leading global supplier of products, solutions, and services within the areas of rolling bearings, seals, mechatronics, services, and lubrication systems. SKF was founded in Gothenburg Sweden in 1907, and presently has 140 production facilities in 32 countries and a presence in 130 countries. Annual revenues in 2010 were $9.6 billion. As early as 1920, SKF was well established in Europe, North and Latin America. Within SKF, sustainability is recognized as both a way of working as well as a key business driver necessary for achieving long-term growth. We recognize that there are three essential reporting blocs in sustainability: Economic, Social, and Environmental performance. SKF was included for the eleventh year in the Dow Jones Sustainability Index and the tenth successive year in the FTSE4 Good Index Series. This presentation will discuss the long history that SKF has regarding its sustainability efforts and the ultimate culmination of our SKF Care and Beyond Zero Program, which is presently the foundation for our ongoing sustainability initiatives.
SKF's Executive Summary (kB .pdf) -- coming soon