2. Agenda
Introduction
Technology – Ever changing world
Dudley’s Strategy
Innovation in Finishing
Key Points
- Timing
- Facility
- New Skills & Training
Volumes - 2012
Finishing Organizational Changes
Process Details – Q & A
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3. History of Gentex and Essilor of America
Largest manufacture in the Dudley, MA area
Produce corrective lenses and coating for ophthalmic
industry worldwide
Gentex optic was acquired by Essilor in 1995
Employees 400 people, 12 hour shift intervals, 7 days a week
Forbes magazine list “The World’s Most Innovative
companies”
Iconic products such as, Varilux and Crizal.
Three R&D centers US, France and Singapore
Joint- Ventures
3
4. The World Around Us
The world gets smaller each and every day
The internet now gives everyone the ability to know
everything
The rate of change is mind blowing
Finding that unique niche that separates you from
everyone else is not so easy
Continuously improving everything everyday is not a
luxury
Innovation is a “must have”
Change is inevitable. Those that win aren’t afraid of it
and know how to manage it
4
5. Technology
What are some of the new technology in last 25 years
that have revolutionized our society, industry,
culture, mankind…..
– Internet
– Cell Phone
– GPS
– RFID
5
6. The need
Unit Cost Gap
Unit Cost
Dudley Competition
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9. Innovation in the Finishing Dept.
►Plan/Communication started Jan 2012
►Auto-sort = A gateway technology
►Integration of the Technologies
►Automation Phase 2
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10. Current State - Dudley Inspection Lines Today
½ ½ ½
½ ½ ½
Label Label Label
Runner Runner Runner
Maker Maker Maker
Manual Manual Manual
Degate Degate Degate
Manual Manual Manual Manual Manual Manual
Sort Sort Sort Sort Sort Sort
Manual Manual Manual
Verify Verify Verify
Inline Inline Inline
Audit Audit Audit
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11. Future State - New Inspection Process
Loader
Auto Auto Auto
Degate Degate Degate FIP Phase II
Integrated System
Auto
3 Automatic Degating
Sort machines
4 ASM (Cosmos)
8 Universal Operator
Auto Stations
Sort (Sort/Verify/Audit)
Universal Universal
RFID Carrier Transport
and SCADA
Auto
Sort
traffic control.
Universal Universal Capacity 60K lenses in 24
hours
Auto
Sort
Universal Universal
Auto
ASM by-pass Unloader
Accum
Universal Universal
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14. Second Floor West
Distr Existing Facility Layout 8/1/12
Auto, Eng Offices
Maint Phase II Coating
QC Auto
Break
QC QC Meeting QC Blue Rm
Offices Raw Mat’l Second Floor North
Second Floor South
Molding
Clear
Finishing
Distr
QC
Polar Molding
QA EH&S
Distr
Molding
Clear
First Floor South
First Floor North
15. Training
What?
Log in training
Safety Overview
When?
Operational Training
March - August 2012
FIP II DATA ,Trend, OEE Matrix
Reporting Capability Overview
Training
Basic Maintenance
Skilled Maintenance -AUTO TECH
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19. Organizational Changes
New Positions created from FIP
– Auto-Tech
– Loader/Unloader
– Maintenance Lead
Positions not required in FIP
– Picker/Label maker
– Runner
– Degator (Secondary)
– Sorter for 80% of Clear Products
– Mispack checker 19
20. Organizational Changes
Reduction of 38 positions total across the 4 shifts
Q1 Q2 JUL AUG SEP Q4
DL 28.5 29.5 29.5 20 20 20
We have a reduction in force policy:
Voluntary lay-off option
Temporary staff
Final Notice
Outplacement Services
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21. How Can I Prepare Myself for the Future?
LEARN Everything You Can!
– Take part in all of the innovation projects and training.
These are skills you can take with you anywhere.
– Continuous Improvement will be very different in the
future here but look what you have already learned?
• 7 wastes
• 5S
• Structured Problem Solving
• How to work as a Team
• …………and more to come!
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Emphasizing the speed of change and the ever changing world we live in
Asking the questions before showing the answers to bring the group into the conversation/presentation. Create a realization of wow, when you step back and see the big picture
The business case around us needing to have a strategy to overcome the ever important unit cost gap between us and the Essilor facilities in other countries, other companies, etc.
To overcome the above the following strategy has been devised for Dudley
Important to talk about this being a long standing plan in the works for some time – 2008. Inspection system is very good in Dudley, but still subjective. The Auto-sort helps with that problem and is our gateway to Technology. Once that piece was confirmed as a Innovative solution the past few years focus has been around integration of that into our manufacturing process along with what else that could give us the ability to do – Conveyors, ASDM, Accumulation of lenses in process.
High level map of the new process. Point out the new technologies in green; what they are, what they do and the benefit that they bring to our process
More firm dates will be communicated through your local managers as they become firm and are relevant to your functional area
Date of Cafeteria closing is not determined at this time, but it will be very soon. The facilities team is in the final stages of determining lay-out of the new line and what area will be free for a potential area to be set-up. The space will be smaller than currently available, so breaks will have to be spread out and other break areas may need to be utilized. As soon as more firm details are available communication will occur
Dotted line is where the FIP ph.2 will end as known today. Important to note the flow and how in the process of construction and line set-up that it will change and a door to Molding will be used for the majority of truck traffic
More details to be shared on training specifics and timing through your functional managers and teams in the coming weeks, months.
Volumes as we see them right now – Overall above budget, with a slight drop in Q2 and then again in Q4
Clear volumes are strong and above budget!
Polar is below budget by nearly 1.5k lenses a day, but they are stable throughout the year. The biggest contributor is Kbco and not buying as much as they initially anticipated last fall
Atuo-Tech is a production position that will be capable of operating the FIP line as whole. This is a new position to the organization that requires some pre-requisite skills in mechanical, electric, database and Automation
Factors can change the total number of 38, but from the information we have this is what we see currently A voluntary lay-off option will be offered. Applications will be accepted and will be reviewed for feasibility. We can not guarantee that all requests for voluntary lay-off can be honored. Temporary Staff would then be impacted and assignments will end. Currently, there are 26 temporary team members. We will be meeting with these team members in a follow-up meeting separately. Any team member on active final notice will be impacted. Further steps for reduction in force if needed will be explained in detail in April. Outplacement services – A comprehensive plan for transitional services such as on-site outplacement assistance, assistance with filing for unemployment, and other means of assistance is being developed. This will also be communicated during the April timeframe.
