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LEA Lean Summit 2016
Learning Lean, Lean Learning
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©2013 Milliken & Company
Milliken & Company
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Privately held
Over 30,000 products
7,000 associates
Operations throughout Americas, Europe and Asia
Consulting throughout Americas, Europe and Asia through
Performance Solutions by Milliken
©2013 Milliken & Company
We were 150 Years Young in October 2015
Milliken & Company
©2013 Milliken & Company
Key Markets
Specialty Chemicals Intermediates • Textile Chemicals • Plastic Additives • Specialty Colorants • Carpet Cleaning
Floor Coverings & Interiors Commercial • Contract • Residential • Hospitality • Napery & Drapery • Office Fabrics
Protective & Performance Textiles
Performance Apparel Fabrics • Workwear Fabrics • Military Fabrics • Airbags • Nonwovens
Industrial Products Composites • Belt & Hose Textiles • Innerduct • Tire Cord • Core Materials
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Over 125
Corporate Initiatives
Era of People Excellence
1980 to 1985
1985 to 1990
Era of Process Excellence
1990 to 1996
Era of Business Excellence
From 1996
Implementation of the Milliken Performance System
1980
1985
1990
Today
Journey in Operational Excellence
©2013 Milliken & Company
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The Milliken Performance System
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• Consultant support, who rigidly taught us tools.
• Management team had to learn what was lean was ‘all about’
• Engage with our associates in the same way we’d learnt about maintenance and quality a decade earlier.
Learning Lean, Lean Learning
©2013 Milliken & Company
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Wellington Plant, Bury
Learning Lean, Lean Learning
©2013 Milliken & Company
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With Purposeful Play
Learning Lean, Lean Learning
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With Purposeful Play
Learning Lean, Lean Learning
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With Purposeful Play
Learning Lean, Lean Learning
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With Teams
Learning Lean, Lean Learning
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Lean Application, Problem Solving
• Bronze – Team works on a project to gain confidence and enhance skills from lean training.
• Silver – With greater confidence, the team splits into smaller groups to self manage projects.
• Gold – Now with confidence and project management skills, large projects worked on.
Learning Lean, Lean Learning
Bronze Silver Gold
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Bronze Phase – Team works as one group on identified issues.
Learning Lean, Lean Learning
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Silver Phase – Group splits into smaller teams to enhance skills from Bronze section.
Learning Lean, Lean Learning
Recycling TeamPete WildDarren MeliaNeil Hall
As can be seen from the sample general waste we have scope to improve our recycling by segregating items such asCansGlassPlasticsTextilesPlastic cupsPaper
The team are looking at ways to improve our recycling byIntroducing bins for segregation to be placed in the best places around the plant Involving outside agencies to help us better understand what can and can not be recycled
©2013 Milliken & Company
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Silver Phase – Group splits into smaller teams to enhance skills from Bronze section.
Learning Lean, Lean Learning
©2013 Milliken & Company
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Gold Phase – Major projects undertaken requiring focused approach over months.
Learning Lean, Lean Learning
©2013 Milliken & Company
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Gold Phase – Larger projects undertaken.
Learning Lean, Lean Learning
©2013 Milliken & Company
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Solving problems outside of the manufacturing arena
Learning Lean, Lean Learning
©2013 Milliken & Company
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With Support, Coaching and Mentoring
Learning Lean, Lean Learning
From Shift Manager to Continuous
Improvement Leader in 24 hours or your
money back!
©2013 Milliken & Company
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Standard Work for Leaders/ Kamishibai
• Kamishibai is a form of storytelling using visual cards/boards.
• Adapted for Standard Work in the Office environment
• Used as a Self Audit
Learning Lean, Lean Learning
Monday Tuesday Wednesday Thursday Friday08:00 08:15 Start Up Start Up Start Up Start Up Start Up08:15 08:30 Emails Emails Emails Emails Emails08:30 08:4508:45 09:0009:00 09:15 Tool Box Talk Tool Box Talk09:15 09:30 Review OFIs Review OFIs09:30 09:4509:45 10:0010:00 10:1510:15 10:3010:30 10:45 Glass Wall Glass Wall Glass Wall Glass Wall Glass Wall10:45 11:00 Lean Team Lean Team Lean Team Lean Team Lean Team11:00 11:15 Risk Management11:15 11:3011:30 11:45 QM/Kaizen Review11:45 12:0012:00 12:1512:15 12:3012:30 12:4512:45 13:0013:00 13:1513:15 13:3013:30 13:4513:45 14:00 TIMWOOD Preparation TIMWOOD Preparation TIMWOOD Preparation TIMWOOD Preparation TIMWOOD Preparation14:00 14:1514:15 14:3014:30 14:4514:45 15:0015:00 15:1515:15 15:3015:30 15:4515:45 16:00
Lunch Lunch Lunch Lunch Lunch
TIMWOODReview or Business
Review Slides
TIMWOODReview or Business
Review Slides
TIMWOODRisk Management
C I Activity / Support
TIMWOODRisk Management
C I Activity / Support
TIMWOODRisk Management
C I Activity / Support
Action OFIs Action OFIs
Sacred Time
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Involving Associates In Strategy Deployment
Learning Lean, Lean Learning
©2013 Milliken & Company
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Benchmarking/ Recognition Visits
Learning Lean, Lean Learning
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Our Key Learnings
Learning Lean, Lean Learning
If it doesn’t look or feel right, it probably
isn’t.
©2013 Milliken & Company
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Our Key Learnings
Learning Lean, Lean Learning
You will only get out what you put in. Lean
Leadership is a must.
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Our Key Learnings
Learning Lean, Lean Learning
It is of no use to learn the Lean tools if you do not learn when and how to
deploy them.
©2013 Milliken & Company
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Our Key Learnings
Learning Lean, Lean Learning
Lean is about people.
©2013 Milliken & Company
Learning Lean, Lean Learning
Insert Video
©2013 Milliken & Company 29
Learning Lean, Lean Learning
Questions, thank you.