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FLEXO Magazine : June 2008
PLANTS & PROCESSES the way, inspire a shared vision, challenge the process, enable others to act, encour- age the heart. Every leader's mission: "Put forth a unique image of the future, for the common good." Kevin Cooper, assistant professor, California Polytechnic State University, saw Lean manufacturing as a management system, not a program. He encouraged Lean-minded printers to turn their atten- tion to focusing on the process; then sta- bilizing, standardizing and improving it. Speaking to how Lean is applicable in a printing culture, he said, "Aim for perfection. Remember, you can't make fundamental change through incremental steps." Elaborating on the point, Cooper stated, "Culture has to do with leadership. Change the guidelines about what you are shooting for. Behave differently and act differ- ently. Culture will shift to reflect the values you exhibit." more. We're in the make-ready business," he proclaimed. "As such, we must train accordingly." Calls to action were numerous. Among them: · Chris Marks, Stephens Graphics, said, "Controlling material consumption is an increased opportunity for profit." . Humza Igram, Cedar Graphics, rec- ommended, "Don't forget to combine Lean and Six Sigma. They go hand- in-hand." ment; simple techniques like Pareto Analysis, open the possibility of focusing attention on problems in priority order." VALUES IN ACTION Russ Bookbinder, of San Antonio Spurs Sports and Entertainment, to no one's surprise, talked team. "A true team is the key ingredient to being successful," he said. "Without it, you have divisiveness. Everyone sets out to protect his or her own territory. Any organization should be built on integrity, car- ing and success. Each of the three has a considerable impact on all stakeholders." Pearls of advice that Bookbinder offered to the printing audience included, "Be all about clarity and accountability. Consistency and process control is critical to suc- cess. Avoid 'analysis paralysis.' Keep your vision and priorities in focus. Allocate resources accordingly and always have a succession plan that identifies up and coming leaders." Rick Green of Green Communication Strategies also brought an element of entertainment to the Continuous Improvement Conference crowd. In a feature presentation, designed to cap things off, he delivered his Printer's Culture Change Rap: 'We're printers and that's ok. Even with machines, We ain't going away! Kicking butt and taking names OnÒ' brings us Misery and shame. So, maximizing Human Capital should be The name of the game. We all can dream Of a new Working scheme, Where work is Jim. No Attila the Hun. Workers with gun, Then on the run. We're printers And that's ok. Let us be led To a bright new way!". WORLD-CLASS TRAI N I NG Tim Crawford, of Mimeo, in Memphis, TN, noted that the economic reality of the printing business today comes down to one simple fact, "Capacity exceeds de- mand." To differentiate his operation from the crowded field, Crawford implemented what he described as a Process Activated Training System (PATS). It hinges on three critical steps: . Develop training quickly. · Execute training immediately. · Document best practices. "Keep to a lO-step learning process," Crawford advised. "Discuss and demon- strate exactly how proactive best work practices will prove a direct benefit in your plant." Fisher, the prognosticator of culture shock, followed Crawford at the podium and elaborated on his assessment of cur- rent conditions and the developments that they will spawn. "Technology- computerization and automation is greatly advancing. More emphasis is being placed on maintenance. Higher expectations- immediate production, larger returns and reduced costs; translate into smaller staffs and greater utilization of equipment. "We're not in the printing industry any- - JUNE 2008 FLEXO · Chris IlIa, J aps-Olson, speaking on Cellular Flow Manufacturing, offered, "When processes are balanced, the product flows continuously, mate- rial movement is minimized, wait time between operations is reduced, inventory is reduced and productivity increases." . Flory Spina, Transcontinental Printing, embraced metrics. "Measure results of each process. Maintain control. Establish baselines for future im- provements. Determine that you are doing the right things and doing them well." · Chip Stine, Sandy Alexander, which operates a flexo plant in Staten Island, NY, detailed essential steps to sus- tainability. "Reduce the generation of waste through prudent purchasing. Buy reusable/returnable ink totes. Recycle plate chemistry containers. Size paper to best fit the job." · Dr. Raj endrakumar Anayath, Print Media Academy, Heidelberg, India, observed, "The print industry is fac- ing cutthroat competition in price, performance and delivery. Instead of investing huge sums of money on various qualities testing equip- www.flexography.org