Firm analyzes, teaches and implements manufacturing processes that lower cost of manufacturing for AllPak, Bay Cities Container, Gallo Glass and Mark Container
Seattle, WA - July 15, 2002 - P2 today announced the formation of its company that helps manufacturers realize a quantum difference in productivity and cost efficiency through implementation of lean manufacturing strategies. P2 helps companies reduce waste and adopt methods to facilitate long-term change. Bay Cities Container, Mark Container, AllPak and Gallo Glass Company utilize P2's services to help them identify the value stream, organize for success, lower the cost of manufacturing and improve return on investment (ROI).
"In today's challenging economic climate, packaging companies are re-thinking traditional definitions of productivity," said Wayne Millage, general manager, AllPak Container and Trojan Litho. "It's not enough to simply produce more product - all elements from machine availability to performance and quality must be in sync in order to achieve the greatest ROI. P2 identifies bottlenecks in the manufacturing process and implements the right methods to lower your overall cost of manufacturing."
Scott Ellis P2's principal agrees. "We measure the process and speak with data to identify and implement the most appropriate lean tool. We then utililize tools similar to General Electric's Workout to draw out and implement a company's best practices. The result is a customized, robust and flexible system that allows people to obtain lasting results."
P2's approach identifies bottlenecks in manufacturing processes. Once identified, P2 will apply their Compass and Mission Aligned People and Process (MAPP) analysis to create or re-align the processes for maximum efficiency. P2's Compass analysis directs companies to the area of most profitable improvement and their MAPP analysis ensures that the improvements will bring real and lasting change to the corporate culture. Customized plans ensure that ownership of process improvements is transferred to those who run and maintain the target processes. The result is lasting change.
"P2's process of building a Visual Workplace and managing the machine centers utilizing OEE numbers has brought the morale up in our plant, increased our overall productivity and delivered a showcase for our customers to visit," said Greg Tucker, president, Bay Cities Container Corporation. "In the end, we wanted a program that would stay with us for the long-haul and because of P2's methods, we were able to give employees what they needed to get the job done and increase the quality of our product. They also trained a champion here at Bay Cities to give the program long lasting legs. This is something you never hear about consultants doing, they always want to come back for that next billing dollar."
P2 has helped companies increase their Overall Equipment Effectiveness (OEE) numbers above the industry standard by as much as 144%. In the case of Bay Cities, after P2 assisted in the implementation of the Visual Workplace, the company saw a 16% increase in machine effectiveness in just four months. P2 hands-on implementation helped Bay Cities to take those best practices learned and apply them on the spot.
According to Barry Johnson, president, Mark Container P2's approach is not just consulting. "Because of the methods P2 uses incorporate lasting change within the organization, everyone - from my office to line mangers and shift supervisors - have become evangelists about the process. We now have prospective customers ask us to come and talk to them about how they can make change within their organization in order to get the same results we have."
P2's Compass analysis locates the tools that provide effective and profitable change. The development of a Visual Workplace is the foundation for process improvement. OEE is then utilized as a balanced measurement of a plant's processes. P2 uses OEE to isolate which of the six big losses of productivity (breakdowns, startup losses, set-up and adjustment, idling and minor losses, speed losses, and quality defects and rework) should be the focus of improvement efforts. Guesswork is eliminated and production numbers are used to guide and measure the improvement. Based on direction provided by the Compass analysis, the appropriate interventions are chosen for the identified loss.
AllPak's Millage added, "Working with P2 is not a contrived experience. They don't build programs outside of the plant and then come back in and say, 'here try it'. I have seen them on the floor with grease up to their elbows next to two crews cleaning a machine down to the bare bones and then building it back up again. This method of leading by example gets people involved in the process and has a greater chance of becoming part of the company culture rather than a consultant that just comes in and drops off a 'how to' manual."
P2 employs the latest concepts on workplace organization, the 7S System to help companies see their workplace, identify waste and then organize them for success. With this foundation in place, P2 bases its actions on the premise that in order to have increases in machine availability, performance and quality (all measured by the OEE number) the workplace must be organized. P2 brings 7S to the forefront and uses it as a basis for change.
P2 is led by is Dr. Scott Ellis and Leslie Pickering. Together, Dr. Ellis and Mr. Pickering have long history of success working in the packaging industry. Dr. Ellis has 13 years of human resource training and development experience within the packaging. Prior to P2, Dr. Ellis was the director of training and development for Pacific Southwest Container. As a licensed Marriage and Family Therapist, (MFT) Dr. Ellis has 16 years experience in private practice assisting individuals and families in growth and change. Through his work with individuals and organizations, he is equipped as a catalyst for healthy change. Dr. Ellis has his Masters and Doctoral degrees in Counseling and Educational Psychology from the University of San Francisco. He holds a Bachelor of Arts in Psychology from California State University, Stanislaus.
Leslie Pickering brings more than 25 years experience in the packaging industry to P2. He draws on his international lean management experience in packaging and manufacturing companies to facilitate the Compass Analyses for P2. Prior to P2, Mr. Pickering was vice president of Technology at Pacific Southwest Container in Modesto, California where he was responsible for process improvement. Mr. Pickering has worked in the area of process improvement in companies throughout the United States and Europe. Mr. Pickering was educated in the formal apprenticeship system of the United Kingdom. His Higher National Diploma in Production Engineering was conveyed by the Business and Technician Education Council. The Technical Education Council awarded him the Certificate in Mechanical and Production Engineering. He is also a graduate of the Mechanical Engineering Craft Studies program of the City and Guilds of London Institute where he received honors as the Apprentice of the Year 1981.
About P2
P2 (read P-squared) provides analysis, training and implementation of lean manufacturing strategies to batch manufacturing of glass, plastic and paper/packaging. The company's unique approach enables clients to employ methods that maximize availability, performance and quality of manufacturing processes to keep the cost of manufacturing low and yield the greatest return on investment. Using time-tested tools, P2's Compass analysis directs companies to the area of most profitable improvement and their Mission Aligned People and Process (MAPP) analysis ensures that the improvements will bring real and lasting change to the corporate culture. P2 works with some of the leading companies in the packaging industry including AllPak, Bay Cities Container, Gallo Glass, LA Corr, Mark Container, and Trojan Lithograph. P2 is based in Renton, WA. For more information on P2's services go to www.PSquaredUSA.com.
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