RESEARCHED & DELIVERED BY
SUPPORTED BY
INTRODUCING
Pre-Summit Shingo Workshop – 8th & 9th June Learn and understand the underlying principles behind The Shingo Prize philosophy and approach, regarded as ‘The Nobel Prize’ for operational excellence and internationally recognised as the blueprint for lean transformation across the whole enterprise.
International Keynote Speakers – 10th & 11th June Gain inspiration to re-invigorate your people, processes and management practices with thought leadership presentations from international keynote speakers for operational excellence and enterprise leaders.
Prize-winning performance – 10th & 11th June Listen to and learn from top-scoring US Shingo Prize winners who have embedded the lean principles of the Toyota Production System and hear from UK Shingo challengers and about their journey through the Shingo Prize model.
20 Break out sessions – 10th & 11th June Select from the three breakout streams structured on the Shingo themes of Cultural Enablers, Focused Improvement and Enterprise Thinking. Whether you are lean enlightened or a lean beginner, you will witness the ‘how’ and ‘why’ of those making exceptional gains in operational excellence.
Hands-on Workshops – 10th & 11th June For delegates wanting enhanced learning, interaction and discussion among delegates then attend the half-day hands-on sessions delivered by some of the best facilitators in lean and culture development.
Post-Summit Best Practice Tours – 12th June See excellence in action with our post-summit best practice tours which give you privileged access to top performing sites, gain vivid demonstrations of excellence in action and see the UK’s first Shingo Prize entrants.
Operational Excellence and Enterprise Leaders Throughout the daytime and evening, like minded enterprise and operational excellence leaders from across Europe will be able to share experiences and information through our informal networking programme based at the Hilton Hotel.
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AGENDA 8 Day One, Day Two & Day Three
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AGENDA Day Four & Day Five
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Keynote Speakers Day One
7
10
Stream One Speakers Lean Enterprise
14
Pre-Summit Workshop
Day One Day Two
15
Summit Workshops
16
Factory Tours
17
Networking Spectacular
18
Hotel Booking
19
Booking Form
Stream Two Speakers Cultural Enablers Day One Day Two
Keynote Speakers Day Two 12
Stream Three Speakers Foucused Improvement Day One Day Two
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INTRODUCTION Dr Julie Madigan Chief Executive, The Manufacturing Institute
We will all be severely tested in 2009 and beyond. Those who challenge convention to make creative use of adversity and strive to actualise peak performance will emerge strongest and fittest for the future. Change is upon all of us and all of us must continue to change the way we operate if we hope to survive and grow.
Whatever your specialist sector, size or marketplace – whether you are running a hospital, a heavy engineering business or a government department – there’s an urgent need to build a value-adding enterprise based on the application of ‘true north’ lean principles across the entire organisation. The Summit will present best practice from both sides of the Atlantic across three key Shingo themes of Cultural Enablers, Focused Improvement and Enterprise Thinking – with the goal of real business and operational results always firmly in sight. Whether you are just starting out on your transformational journey or are at the mature stage of sustaining and refining improvement, this summit will provide you with the insights and knowledge you require to succeed. We look forward to seeing you in Manchester.
Robert D. Miller Executive Director, Shingo Prize for Operational Excellence, USA
The Shingo Prize is recognised as the world’s most effective blueprint for lean transformation across the whole business enterprise, and the attainment of operational excellence driven by deep cultural change.
Challenging for the Shingo Prize is open to organisations throughout the world. So far the model has profound organsiational change in the USA, Canada, Mexico, and with the collaboration of the Manufacturing Institute in the UK and Ireland, the Shingo Prize continues its international programme of recognising the value of using lean/world-class operational excellence practices to attain world-class status. Testifying to this proven model are many previous US winners, including DJ Orthopedic and OC Tanner who will join us at the Summit to share their success stories.
RESEARCHED AND DELIVERED BY
INTRODUCING
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MONDAY 8TH – FRIDAY 12 TH JUNE 2OO9
UK/US SHINGO SUMMIT AGENDA For the latest information on tours and speakers visit www.ukussummit.com
DAY ONE – PRE-SUMMIT WORKSHOP
MONDAY 8TH JUNE
THE SHINGO APPROACH TO OPERATIONAL EXCELLENCE – DAY ONE
DAY TWO – PRE-SUMMIT WORKSHOP
TUESDAY 9TH JUNE
THE SHINGO APPROACH TO OPERATIONAL EXCELLENCE – DAY TWO
DAY THREE – UK/US SHINGO SUMMIT DAY ONE SUMMIT
D AY O N E 10TH JUNE
STREAM ONE
STREAM TWO
STREAM THREE
L EA N EN T ER P R I SE
CU LT U R A L E N A B LE R S
F O CU S E D IMPROVEMENT
W O R KSHOPS
08:30
Welcome and announcements
08:35
Julie Madigan CEO, The Manufacturing Institute
08:45
Ministerial Keynote – to be announced
09:15
Morning Keynote: Steven Spear, Massachusetts Institute of Technology (MIT)
10:15
Break and visit exhibitors
10:45
DJO LLC (USA)
11:45
Break and visit exhibitors
12:10
Luncheon Keynote: Norm Bodek, President, PCS Inc.
13:40
Break and visit exhibitors
14:00
The Shingo Prize (USA)
15:00
Break and visit exhibitors
15:15
Lean Enterprise Research Centre
16:15
Break
16:20
Afternoon Keynote: Bob Miller, Executive Director, The Shingo Prize for Operational Excellence
17:00
Close
17:15 - 18:45
Drinks Networking Reception & The Shingo Prize Award Ceremony – Museum Of Science & Industry
18:45 - 19:30
Private Tour Inside ‘The Avro Shackleton’ Air and Space Hall – Museum Of Science & Industry
The Manufacturing Institute
United Biscuits
Patheon UK
BAE Systems
O.C Tanner (USA)
The Manufacturing Institute
Lean from our hands-on half day summit workshops
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WEDNESDAY 10TH JUNE
WS1: Are Your Processes a Black Art? WS2 The Waste Within: Lean Office Simulation
Network opportunities to share best practice with your peers
For the latest information on tours and speakers visit www.ukussummit.com
MONDAY 8TH – FRIDAY 12 TH JUNE 2OO9
UK/US SHINGO SUMMIT AGENDA For the latest information on tours and speakers visit www.ukussummit.com
DAY FOUR – UK/US SHINGO SUMMIT DAY TWO SUMMIT
D AY TWO 11TH J U NE
THURSDAY 11TH JUNE
STREAM ONE
STREAM TWO
STREAM THREE
L EA N EN T ER P R I SE
CU LT U R A L E N A B LE R S
F O CU S E D IMPROVEMENT
08:30
Welcome and announcements
08:35
Stuart Smalley, Department of Health
08:45
Morning Keynote: Max Brown, Director, O.C. Tanner Company (USA)
09:40
Break and visit exhibitors
10:00
Drew Locher (USA)
10:55
Break and visit exhibitors
11:10
Department of Work and Pensions
12:00
Break and visit exhibitors
12:15
Luncheon Keynote: John Toussaint, CEO, ThedaCare (USA)
13:45
Break and visit exhibitors
14:00
Ultraframe (UK) Ltd
15:00
Break and visit exhibitors
15:25
IfM, Cambridge University
16:10
Closing Keynote: To be announced
16:50
Close
HG Berry & Co
Blackpool, Fylde & Wyre NHS
Southport & Ormskirk Hospital
Nortel
BAE Systems, C-TEC
Warwick Business School
Manchester business School
Royal Devon & Exeter NHS
DAY FIVE – POST-SUMMIT FACTORY TOURS Maximum delegates: 30
PZ Cussons (UK) Ltd
Maximum delegates: 30
BAE Systems
Maximum delegates: 30
HJ Berry & Sons Ltd
Maximum delegates: 16
Ultraframe (UK) Ltd
Maximum delegates: 30
Tours depart the Hilton Hotel
14:00 - 15:00
Tours return the Hilton Hotel
WS3: How to Build a Culture of Capable and Committed People WS4 The Waste Within: Lean Office Simulation
FRIDAY 12TH JUNE
SIEMENS
08:00 - 09:00
W ORK SHOPS
Additional tours will be announced on www.ukussummit.com
Visit world-class sites on our Post-Summit Factory Tours
See and learn from over 20 best practice presentations
To book and reserve your place call 0800 917 1685 now
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WEDNESDAY 10 TH JUNE 2OO9
KEYNOTE SPEAKERS DAY ONE For the latest information on tours and speakers visit www.ukussummit.com
Steven Spear, Ph.D. Senior Lecturer, Massachusetts Institute of Technology and Senior Fellow, Institute for Healthcare Improvement K EYN O T E SP EA KER
CHASING THE RABBIT: WHY MARKET LEADERS OUTDISTANCE THE COMPETITION AND WHAT GREAT COMPANIES CAN DO TO CATCH UP Dr. Steven Spear has written extensively about how exceptional organisations create competitive advantage through the strength of their internal operations, managing complex design, production, and administrative processes for unmatched performance. His articles, “Decoding the DNA of the Toyota Production System”, “Learning to Lead at Toyota”, and “Fixing Healthcare from the Inside, Today,” have been widely read. Steven will discuss his first book, ”Chasing the Rabbit”, which is heavily based on his work with Toyota and healthcare organisations. He will provide insight as to why market leaders surpass the competition and share ideas for what great companies can do to compete.
Norman Bodek President, PCS Inc. K EYN O T E SP EA KER
GATEWAY TO INNOVATION A pioneer of Lean for over 30 years, Norman Bodek is the author and co-creator of the Shingo Prize, and has been instrumental in finding the amazing tools, techniques, and new thoughts that have revolutionized the world of manufacturing. During the past 30 years, he has visited Japan 66 times, toured over 250 plants, written 5 lean books, and published over 100 Japanese management books in English. Most recently, he has been working with Gulfstream Corporation, the private jet company where 1,000 people went from 16 implemented ideas in 2005 to close to 21,000 in 2006. Norman has discovered that creativity and innovation lies at every level of the organization, be it a new IPHONE or a simple poka-yoke device. He will discuss how it is management’s responsibility to develop and foster an atmosphere that opens every employee to their infinite creative potential.
Robert D. Miller Executive Director, The Shingo Prize, Utah State University K EYN O T E SP EA KER
“THE SHINGO PRIZE FOR OPERATIONAL EXCELLENCE” Robert D. Miller joined the Shingo Prize as the Associate Executive Director in 2006 and has been a Lean practitioner since the birth of Just in Time. Through his senior leadership positions at John Deere, FMC, Herman Miller and The Gates Rubber Company, Bob Miller has experienced the implementation of Lean principles and practices from the Engineering, Production, Materials, Quality, Information Systems and Executive points of view. As vice president at both Herman Miller and Gates, Bob Miller wrestled with selecting from improvement methodologies proposed by a host of consultants and found the principles of Lean to be the most applicable across all business functions. Bob Miller was a principal and senior Partner at the Destra Consulting Group based in Boulder, Colorado where he worked with organisations in many countries and in widely diverse industries to develop and implement strategies for change and business process improvement.
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For the latest information on tours and speakers visit www.ukussummit.com
THURSDAY 11 TH JUNE 2OO9
KEYNOTE SPEAKERS DAY TWO For the latest information on tours and speakers visit www.ukussummit.com
Max Brown Director, O.C. Tanner Company K EYN O T E SP EA KER
THE CARROT PRINCIPLE: COMMUNICATING WHAT MATTERS MOST Mr. Max Brown, prior to joining O.C. Tanner, lived in Shanghai, China running programs for multi-national corporations and setting up a small retail business in 21 locations. With his experience in leadership training, speaking, and facilitating around the world, Max brings a global perspective to the challenge of motivating people. He will show you how to create powerful recognition experiences to retain and engage employees. Based on the award-winning book, “The Carrot Principle”, Max will illustrate how companies spread the power of recognition across multiple, far-flung locations. You will learn that respect for the individual is the foundation of great recognition and ultimately better business results. He will teach you how to simplify your recognition programs, and provide a few simple ideas that can increase their impact.
Dr. John S. Toussaint, MD President & CEO, The ThedaCare Center for Healthcare Value K EYN O T E SP EA KER Dr. Toussaint served as president and chief executive officer of ThedaCare, Inc. from March 2000 until April 2008. During his tenure at ThedaCare, he introduced the ThedaCare Improvement System (TIS), which is based on the Toyota Production System. The culture of continuous improvement has allowed ThedaCare to reduce patient errors, improve outcomes and deliver better quality care. This methodology was used to create Collaborative Care, which is a revolutionary inpatient care model that has produced remarkable results including zero medication errors and 100% reliability in quality process measures. The ThedaCare improvement system has saved ThedaCare $25 million in healthcare expense without layoffs and has reduced the total spend for employers who have chosen to direct contract with ThedaCare. ➔ Under Dr. Toussaint’s watch, ThedaCare’s revenues grew from $230 million to $550 million ➔ ThedaCare and Dr. Toussaint’s work have been featured in publications including The Wall Street Journal ➔ The Milwaukee Journal Sentinel, Modern Healthcare, and The Harvard Business Review
Stuart Smalley Former Head of International Developments, Department of Health K EYN O T E SP EA KER Between 2001- 2009, Stuart held the post of Head of International Developments at the Department of Health. This role entailed the management of bilateral relationships and the international health programme, supporting Ministers and providing health expertise to overseas governments – China, India, Libya and the Middle East. Stuart recognised that globally, politicians and healthcare leaders are increasingly concerned about the rising costs of healthcare. Set in the context of changing demographic influences and tighter regulation, this presentation will address the dynamics of market forces and shifting patterns of healthcare matched with the effect on income streams for hospital providers. With greater pressure on public spending, new and innovative ways have to be found to make healthcare organisations more efficient and effective than ever before. Whole systems have to be improved.
To book and reserve your place call 0800 917 1685 now
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LEAN ENTERPRISE
WEDNESDAY 10TH JUNE
STREAM ONE SPEAKERS DAY ONE For the latest information on tours and speakers visit www.ukussummit.com
The three breakout streams of the UK/US Shingo Summit are structured around the Shingo Prize model, a model taught by Shigeo Shingo that recognises the vital philosophies of a lean management approach. The full potential of lean is realised only when the most critical aspects of an enterprise share a common platform of lean principles, management systems and tools. While it is expected that organisations develop some unique elements to their culture, it is also expected that lean principles become a common, uniting part of each culture. Top-level leadership, staff, and business processes should exemplify the same principles, systems, and tools as do the operational components of the enterprise. Come and learn from those companies who have developed a consistent lean enterprise culture.
Jerry M. Wright, P.E. Vice President, Lean and Enterprise Excellence DJO, LLC S TR EA M O N E L EA N EN T ER P R I SE
RISE FOR THE PRIZE A 2006 Shingo Prize winner, DJO is a global medical device manufacturer that has used the key elements of the Shingo Prize business model to transform its culture. Since starting its lean journey in 2000, DJO has benchmarked Shingo Prize winners and other lean companies in order to see what is required to truly change the way a company does business. Following the Shingo Prize model, DJO leaders created the DJO Way, or the way that their company goes about driving its mission and business objectives. This cultural transformation has resulted in a business that has tripled in revenues while just doubling in costs over a 4 year period. He will share DJO’s “Rise for the Prize” experience and lessons learned on the journey.
Shaun Barker Director The Shingo Prize, Utah State University S TR EA M O N E L EA N EN T ER P R I SE
INTRODUCTION TO THE SHINGO PRIZE This presentation will introduce the Shingo Prize Model and the underlying principles behind the Shingo Prize philosophy and approach. You will get an in-depth look at the levels of transformation and the various business processes that are presented in the model along with an understanding of the transformational path ahead of your organisation in pursuing a lean culture. The presentation will address the following: ➔ Adopting the Shingo approach to operational excellence: optimising lean and six sigma ➔ Taking lean principles beyond manufacturing and into the company culture ➔ Using the Shingo Prize as a model for operational excellence
John Bicheno Senior Research Fellow Lean Enterprise Research Centre, Cardiff Business School S TR EA M O N E L EA N EN T ER P R I SE
NEW THINGS FROM OLD GUYS Shingo was, of course, one of the early and great pioneers of lean. His ideas on Changeover and Poka yoke are well known. But what about his other contributions – on problem solving, improvement, scheduling, and problem identification? Likewise there is much to learn from other pioneers. Demming, the TWI developers, Emery, Ohno, Toyoda, Smiles, Juran, Kingman, Ackoff, Burbidge and Woollard are all worth another look. These ‘greats’ worked in hard times, much like now. John Bicheno was born in South Africa, graduated in engineering and spent 12 years in industry and local government in South Africa. His books have sold over 100,000 copies. These include Implementing ”JIT”, ”Cause and Effect Lean”, ”The New Lean Toolbox”, ”Six Sigma and the Quality Toolbox”, and ”Operations Management”.
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For the latest information on tours and speakers visit www.ukussummit.com
LEAN ENTERPRISE
THURSDAY 11TH JUNE
STREAM ONE SPEAKERS DAY TWO For the latest information on tours and speakers visit www.ukussummit.com
Drew Locher Principal Change Management Associates S TR EA M O N E L EA N EN T ER P R I SE
THE COMPLETE LEAN ENTERPRISE – INCORPORATING THE OFFICE IN VALUE STREAM MANAGEMENT Drew Locher, a lean expert co-authored a book titled ”The Complete Lean Enterprise: Value Stream Mapping for Office and Administrative Processes” that received a Shingo Prize in 2005. Drew’s most recent book is titled ”Value Stream Mapping the Lean Development Process”. In this workshop, Drew will review the 8 basic wastes in the context of non-production processes. He will explore lean thinking and discuss how it is applied to information intensive processes such as value stream mapping, the assessment and planning tool of lean practitioners. You will learn how to use the value stream mapping tool to assess and re-design any business process.
Martyn Craske Lean Programme Manager Department of Work and Pensions S TR EA M O N E L EA N EN T ER P R I SE
THE BEGINNER’S GUIDE TO ELEPHANT WRESTLING The Department of Work and Pensions is one of the largest Whitehall departments with 120,000 employees serving 22 million customers out of around 1,000 locations. This session explores the challenges of rolling out the DWP Lean approach, which has produced exceptional results in small local pilots, to a sustainable, enterprise wide solution. Martyn brings to the Lean Programme a wealth of experience drawn from both public and private sector change programmes, with organisations such as Norwich Union and Capita. Within the public sector, Martyn headed up the change programme of the (UK) Work Permit system within the Department for Education and Employment.
Dominic Oughton Senior Industrial Fellow University of Cambridge S TR EA M O N E L EA N EN T ER P R I SE
STRATEGY DEVELOPMENT, VISUALISATION AND DEPLOYMENT Policy Deployment is a planning and implementation system, based on scientific thinking, employee involvement, and respect for the individual. At the strategy level, Policy Deployment provides leadership with the necessary principles, systems, and techniques to carefully align key objectives and execution strategies – while empowering the organisation through cascading levels of detail, to achieve its objectives. Because so many people are involved, clarity is critical: the simplicity of “on a page” thinking and visualisation helps keep everyone, literally, on the same (single) page, pointed in the same direction. In this presentation, Dominic will illustrate the principles of strategy development, visualisation and deployment.
Mike Price CEO Ultraframe (UK) Ltd S TR EA M O N E L EA N EN T ER P R I SE
IMPLEMENTING AND SUSTAINING THE ULTRAFRAME “VISION PROGRAMME” In the early 2000s Ultraframe, though profitable, became exposed as market forces took effect. Although improvement initiatives were taking place in pockets of the business there was a lack of understanding of the bigger picture and overall business priorities and employee relations and communication was poor. A ‘Vision Programme’ was developed to transform the culture and align everybody’s efforts under one vision. As a result, productivity increased and savings of more than £1.5m were realised. This presentation illustrates Ultraframe’s principle and systems based approach to continuous improvement and will focus on their ‘breakthrough’ projects that took their transformational vision into reality.
To book and reserve your place call 0800 917 1685 now
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CULTURAL ENABLERS
WEDNESDAY 10TH JUNE
STREAM TWO SPEAKERS DAY ONE For the latest information on tours and speakers visit www.ukussummit.com
The three breakout streams of the UK/US Shingo Summit are structured around the Shingo Prize model, a model taught by Shigeo Shingo that recognises the vital philosophies of a lean management approach. Cultural Enablers is the first dimension that makes it possible for an organisation to start a lean transformation journey, progress in their understanding, and ultimately convert to a lean culture. Getting people to take the initiative is a big key step to sustaining lean. To make lean a way of life, it not only requires building the skill sets of it, takes building not only the skills sets of individuals, but also engaging the hearts and minds of all employees. Come and learn what the leading-edge companies have done to create a work culture that underlines the tools and systems to sustain an environment of lean.
Paul Glossop & Graham Canning Principal Consultants The Manufacturing Institute ST R EA M T WO C ULT U R A L E N A B LE R S
GROWING FROM WITHIN: WHAT TO DO WHEN THE CONSULTANTS HAVE GONE This breakout session is ideal for enterprise leaders and directors responsible for the successful implementation of lean within their organisation or supply chain. It is of particular benefit to those who want the real impact and difference made to be driven bottom-up, rather than by a small number of improvement specialists. By attending this session you will: ➔ Gain a practical understanding of A3 Problem Solving and Visual Management ➔ Understand the behaviours you need to exhibit as a leader to develop and sustain your improvements ➔ Develop methods to harness the creative power of all your organisation to solve problems at ground level ➔ Gain tools for sustaining and growing your own improvement systems and processes
Andrew Chatfield & Peter Webster Executive Director & Production Manager Patheon (UK) Ltd ST R EA M T WO C ULT U R A L E N A B LE R S Patheon is a leading global provider of contract dosage from development and manufacturing services to the pharmaceutical and biotechnology industries. Employing more than 4,700 highly-skilled staff, Patheon’s network of modern manufacturing facilities located in North America and Europe offer best in class capacity. Full details of the lean implementations at Patheon’s UK site will be announced on the www.ukussummit.com
Michael Cordon Manager, Training & Development O.C. TANNER, USA S TR EA M T WO C ULT UR A L EN A BL ER S
BUILDING CULTURE AND CAPABILITY – LESSONS FROM A SHINGO PRIZE WINNER O.C. Tanner helps companies appreciate people who do great work, producing customised awards for many of the world’s leading businesses, including many of the Fortune 100. Their corporate headquarters are in Salt Lake City, Utah. At the end of the 1990s, the company made innovations in short-lead, just-in-time manufacturing processes and automated distribution and it also reorganised its workforce into cross-trained teams so that everyone throughout the organisation truly understood the goals of the company and was focused on exceeding customer expectations. Michael Cordon will explain how O.C. Tanner built its culture of capable and committed employees, a process which earned them the internationally recognised Shingo Prize. The Shingo Prize promotes world-class manufacturing and recognises companies that excel in productivity and process improvement, quality enhancement, and customer satisfaction.
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For the latest information on tours and speakers visit www.ukussummit.com
CULTURAL ENABLERS
THURSDAY 11TH JUNE
STREAM TWO SPEAKERS DAY TWO For the latest information on tours and speakers visit www.ukussummit.com
John Woodruffe Managing Director HJ Berry & Sons Ltd S TR EA M T WO C ULT UR A L EN A BL ER S
LEAN GREEN FIGHTING MACHINE There is no greater measure of respect for the individual than creating a work environment that promotes both the health and safety of employees and the protection of the environment and the community. Under the leadership of John Woodruffe, HJ Berry & Son Ltd, has recently taken a string of top honours for its sustainable approach, with no less than six national awards for its green manufacturing processes notched up in 2008. John will discuss and illustrate the lean journey at HJ Berry, examining how their elimination of waste, adding value and process improvement is directly aligned to environment and safety systems. John will also share his insights into the role of the Managing Director in driving a lean programme within a family business.
Alex Lewis
Steve Collier
Nicola Eagleton-Crowther
HR Director BAE Systems
Manufacturing Manager C-TEC
Make It Campaign Manager The Manufacturing Institute
ST R E A M T W O CU LT U R A L E N A B LE R S
HIT OR MYTH? During a recession positive talent management is more crucial than ever, both to prepare for the upturn and to secure industry’s long-term future. Hear how leading companies use the Make It campaign to attract future talent by debunking the myths of ‘boring industry’, highlighting its challenges and rewards for ambitious school leavers while developing the skills and motivation of existing young employees by making them ‘champions’ for their sector.
Dr David Bamford Senior Lecturer in Operations Management Manchester Business School S TR EA M T WO C ULT UR A L EN A BL ER S
CRISIS LEADERSHIP Leadership ensures the organisation has a visionary management team able to champion and sustain the concept throughout the journey. But what do you do as the leader when the unexpected happens and crisis occurs? David’s presentation is ideal for leaders who want to know the approaches and tools to enable leadership within a crisis. A former Director of the NHS Leadership Programme at Manchester Business School, David has an industrial and commercial background which, following an initial qualification in mechanical engineering and an Honours degree in Management, culminated in the position of Operations Manager (Pharmaceutical) for Courtaulds Plc in Wrexham. The position was created to manage and lead manufacturing and assembly operations and involved establishing complex logistical relationships with worldwide suppliers, contractors and customers. David also provides ongoing strategic guidance at board level for a number of manufacturing and service organisations.
Sharon Hendry Service Improvement & Development Manager Southport & Ormskirk Hospital S TR EA M T WO C ULT UR A L EN A BL ER S
“LETS LEAN IT – TRANSFORMATION OR TOOLS?” Details of this presentation to be announced.
To book and reserve your place call 0800 917 1685 now
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FOCUSED IMPROVEMENT
WEDNESDAY 10TH JUNE
STREAM THREE SPEAKERS DAY ONE For the latest information on tours and speakers visit www.ukussummit.com
The three breakout streams of the UK/US Shingo Summit are structured around the Shingo Prize model, a model taught by Shigeo Shingo that recognises the vital philosophies of a lean management approach. The Continuous Focused Process Improvement dimension is based on a tools & techniques understanding and deployment. But maturity through this dimension to Principles is reflected in the depth of organisational transformation through each tool or practice for driving continuous improvement. Come and learn how organisations are applying the tools and techniques of lean, from those in the early stages of lean implementation to organsiations driving a complete lean transformation of their enterprise.
Clifford Burroughs IS Director United Biscuits S TR EA M T H R EE F O C USED I M P R O VE M E N T
SUCCESSFUL LEAN TRANSFORMATION Understanding and managing the factors critical to a multi-site lean transformation programme can be the difference between success and failure for all organisations. In this session, Clifford will explore the key factors for success, including finding the right partners, selecting the right lean tools and systems and ensuring senior level support to the programme. Clifford has had a number of IT roles in UB, initially working in the international division and then moving to the UK as part of a SAP implementation, where he was responsible for the data warehousing and management reporting work streams. In the last twelve months he has taken responsibility for driving enterprise-level, lean thinking across the United Biscuits group and will illustrate in this presentation how lean is a key enabler for UB in driving value and growth.
Phil Astley
Stephen Manley
Head of Production System Design BAE Systems
Production System Design Manager – F35 Lightning II BAE Systems
ST R EA M T H R EE F O C U S E D I M P R O V E M E N T
BAE SYSTEMS CHALLENGE FOR THE PRIZE Phil and Stephen have been responsible for leading the BAE Systems Samlesbury’s site challenge for the Shingo Prize. By attending this session you will learn more about the BAE Systems lean journey and the lessons learned from becoming one of the first UK companies to challenge for the Shingo Prize. Phil is responsible for delivering the lean transformation of Manufacturing Shared Service within Integrated Services at the Salmesbury site. Stephen is a member of the senior management team at BAE Systems Samlesbury in charge of a team of production system design engineers. His current focus is the design and implementation of a lean strategy to take the F35 Lightning II development programme through to production, with a target rate change from 20 days to produce an aircraft down to one. This involves ensuring synergy and cohesion in the principles and methods of lean deployment across international partners.
Carl Tomlinson Principal Consultant The Manufacturing Institute S TR EA M T H R EE F O C USED I M P R O VE M E N T Lean production requires a lean supply chain. But how can you reduce waste and increase speed in your supply chain? The unrelenting pressure of global competition in the marketplace has spurred many manufacturers to an integrated supply chain management that supports that lean philosophy. This presentation will illustrate some of the key principles, systems and tools to developing an integrated approach to your supply chain. Carl has an impressive track record of designing and leading lean transformation programs across multi-layered supply chains, combining a talent for complex problem solving with an ability to motivate people at all levels. By attending this presentation you will understand more of this approach including: ➔ Designing the supply chain around the needs of the customer ➔ Building the supply chain based on Lean principles ➔ Why tools & techniques don’t always deliver the potential expected ➔ Proven pathway to success – applying the right tools and systems in the right place ➔ How to get people out of departmental thinking and boundaries ➔ The importance of developing people
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For the latest information on tours and speakers visit www.ukussummit.com
FOCUSED IMPROVEMENT
THURSDAY 11TH JUNE
STREAM THREE SPEAKERS DAY TWO For the latest information on tours and speakers visit www.ukussummit.com
Dr Zoe Radnor Associate Professor Warwick Business School S TR EA M T H R EE F O C USED I M P R O VE M E N T
TRANSFERRING LEAN THINKING Many public sector organisations are responding to government set efficiency targets by adapting their workplaces for lean. Delegates from both the public and private sector are invited to see, hear and discuss the transfer of lean across sectors and the shared challenges of lean implementation. Against the background of a dramatic rise of lean areas such as universities, the health service, housing associations, planning departments, emergency services and HMRC, you will learn from case study examples how: ➔ The application of lean tools has been used to identify bottlenecks and create flow within public sector processes ➔ How lean creates a culture where people take more ownership of what they are doing to improve what they do ➔ How reduced processing times for public services from 200 days to 12 days and brought payroll errors down from 75% to 2% ➔ Zoe will also identity the success factors and barriers in the implementation of lean
Barry Mulhern
Nick Mulhall
Operations Director Nortel (Belfast)
Lean leader Nortel (Belfast)
ST R EA M T H R EE F O C U S E D I M P R O V E M E N T
APPLYING THE RIGHT LEAN TOOLS IN THE RIGHT PLACE – 5 GOLDEN LESSONS FROM NORTEL Barry has ultimate responsibility for all aspects of the business operation and strategy. For the past 3 years Barry has been driving business transformation through the introduction of lean manufacturing and lean six sigma techniques and principles. Nick is currently leading the lean implementation in Nortel’s Belfast Plant and coordinated their challenge for the Shingo Prize. He has developed and delivered lean training to 190 employees and trained the first wave of lean specialists. He promoted the deployment of LSS in the organisation by holding 3 LSS GIS’s and contributed to global knowledge sharing with suppliers.
Amanda Blessington Chief Pharmacy Technician & Automation Project Manager Blackpool, Fylde and Wyre Hospitals NHS Foundation Trust S TR EA M T H R EE F O C USED I M P R O VE M E N T
LEAN PRINCIPLES IN HOSPITAL PHARMACY This presentation will illustrate the application of lean principles in the redesign of dispensary layout and automated handling system. Amanda will illustrate the tools used that resulted in the reduction of prescription turnaround time by 50% and provided a more responsive and desirable service to patients. Attend this session to learn more about: ➔ Value stream mapping and developing a robust future state ➔ The implementation of workplace organisation, 5S and visual management ➔ Key performance indicators for measures including workload levels, automation reliability and unavailability of medications ➔ Problem solving and error proofing
Tony Cox Divisional Manager – Diagnostics & Professional Services Directorates Royal Devon and Exeter NHS Foundation Trust S TR EAM T H R EE F O C USED I M P R O VEM E N T Details of this presentation to be announced.
To book and reserve your place call 0800 917 1685 now
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MONDAY 8TH – TUESDAY 9TH JUNE 2OO9
PRE - SUMMIT WORKSHOP For the latest information on tours and speakers visit www.ukussummit.com
DAY ONE – MONDAY 8TH JUNE
DAY TWO – TUESDAY 9TH JUNE
09:00 - 17:00
The Shingo Prize Approach to Operational Excellence Workshop Shaun Barker Director, Utah State University, The Shingo Prize for Operational Excellence The UK/US Shingo Summit week begins with the two-day pre-summit Shingo Prize workshop where you will gain an understanding of The Shingo Prize Model and the underlying principles behind The Shingo Prize philosophy and approach. In addition, you will develop a comprehensive working knowledge of The Shingo Prize Guidelines which includes the criteria and methods for assessment of the progress an organisation has made in its lean transformation. The Shingo Prize Model and Business Guidelines have been developed to provide companies with a blueprint for lean transformation and attaining operational excellence that will drive an organisation through the levels of transformation and will build a solid foundation for deep cultural change. The pre-summit workshop is an essential two day programme for companies considering a challenge for the Prize and for individuals looking to become qualified as Shingo Prize examiners. It will provide practical guidance on how to prepare to challenge for the Shingo Prize. Participants will learn how to use the assessment methodologies to drive transformation and how to present and substantiate their achievements and business results.
For challenging companies and potential examiners this workshop will teach you: ➔ The unique capacity of The Shingo Prize Model to guide and drive a lean transformation ➔ How to improve your company’s core business processes
➔ How to reflect your organisation properly ➔ How to become a Shingo Prize Examiner
➔ How to use The Shingo Prize Model as a benchmark
➔ Roles and responsibilities of Shingo Prize examiner team members
➔ How to prepare and challenge for The Shingo Prize
➔ The site examination process
➔ The keys to charts and measurement
➔ How to write a site examination report
‘‘
The Shingo Prize is the only award program in the world focused on lean... and the elimination of ‘muda’
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Masaaki Imai, Chair, Kaizen Institute 14
WEDNESDAY 10 TH – THURSDAY 11TH JUNE 2OO9
SUMMIT WORKSHOPS For the latest information on tours and speakers visit www.ukussummit.com
DAY ONE – WEDNESDAY 10TH JUNE
WORKSHOP CAPACITY : 20 DELEGATES
14:00 - 16:15
Paul Glossop Principal Consultant The Manufacturing Institute S TR EA M T WO C ULT UR A L EN A BL ER S
ARE YOUR PROCESSES A BLACK ART? Does it need that magic touch to keep your automation running? Or perhaps you have variable raw materials which change with the seasons? Paul will demonstrate three secrets to help you get control over your processes, and stop giving away your profit. This entertaining, hands-on workshop will be particularly valuable to people from Chemicals, Pharmaceuticals, and Food sectors, and anybody else who would just like their process to produce good stuff as soon as they press the green button. A combination of case studies and hands-on practical demonstration will make these powerful tools accessible to anyone wanting to manage their processes using evidence rather than superstition.
Bill Tiplady Skills Improvement Practitioner The Shingo Prize (UK) S TR EA M T WO C ULT UR A L EN A BL ER S
THE WASTE WITHIN: LEAN OFFICE SIMULATION This hands-on workshop and office-based lean simulation is ideal for managers and leaders responsible for the productivity and quality of administration and backoffice services, and for those who support organisation-wide improvement strategies. Whether you are an insurance company, manufacturer or housing agency, you will benefit from practical case studies that will enable you to: ➔ Eliminate waste and drive up efficiency from office administration process ➔ Become more responsive to your customer requirements by reducing administration lead times ➔ Remove unwanted stress and pressure on your employees by embedding a culture of continuous improvement
DAY TWO – THURSDAY 11TH JUNE
WORKSHOP CAPACITY : 20 DELEGATES
14:00 - 16:15
Michael Cordon Training Manager O.C. Tanner Company S TR EA M T WO C ULT UR A L EN A BL ER S
HOW TO BUILD A CULTURE OF CAPABLE AND COMMITTED PEOPLE This workshop will discuss how leaders are coaches who help their team members improve performance and meet or exceed expectations. You will learn how to develop the potential of each team member by explaining expectations, training to those expectations, and supporting them. Coaches exist in every walk of life. Your “best coach ever” may have been a great teacher, parent, or colleague who helped you overcome hurdles, realise more of your potential, and ultimately help you to improve your performance. Michael will help you become a great coach, build relationships between team members and leaders, and create a culture of capable and committed employees.
Bill Tiplady Skills Improvement Practitioner The Shingo Prize (UK) S TR EA M T WO C ULT UR A L EN A BL ER S
THE WASTE WITHIN: LEAN OFFICE SIMULATION This hands-on workshop and office-based lean simulation is ideal for managers and leaders responsible for the productivity and quality of administration and back-office services, and for those who support organisation-wide improvement strategies. Whether you are an insurance company, manufacturer or housing agency, you will benefit from practical case studies that will enable you to: ➔ Eliminate waste and drive up efficiency from office administration process ➔ Become more responsive to your customer requirements by reducing administration lead times ➔ Remove unwanted stress and pressure on your employees by embedding a culture of continuous improvement 15
FRIDAY 12TH JUNE 2OO9
POS T- SUMMIT BEST PRACTICE TOURS For the latest information on tours and speakers visit www.ukussummit.com
The closing day of the summit represents an ideal opportunity to witness, first hand and in action, award-winning business improvement, culture change, lean manufacturing and to learn more about the innovative solutions used to solve the issues facing you today. A total of 8 factory tours will be available so you can see and hear first-hand excellence in action. Tickets for the tours must be purchased in conjunction with the two day summit All tours will leave Manchester by coach on the morning of 12th June, and return between 13:00 and 14:00 to Manchester. All tour seats are subject to availability and require advance registration. The Manufacturing Institute, on behalf of the host facility, may have to preclude some attendees from participating in the tours due to the proprietary nature of some of the information presented. Tour participants may be asked to sign a non-disclosure agreement. No cameras, mobile phones or video equipment are permitted on tours.
MAXIMUM DELEGATES : 30
SIEMENS KEY FACTS : ➔ ➔ ➔ ➔ ➔
Number of employees at site: 400. Challenger for the Shingo Prize 2009. Winner of UK Business Excellence Awards 2004. 2004 Best Factory Awards winner. Focused on continuous improvement as part of the working culture.
PZ CUSSONS (UK) LTD KEY FACTS : ➔ ➔ ➔ ➔
Number of employees at site: 120. Unionised workforce. The Manufacturing Institute’s Manufacturer of the Year 2006. Winner of Commitment to Developing People 2005.
BAE SYSTEMS KEY FACTS AND ISSUES : ➔ ➔ ➔
Number of employees at site: 6,000. Visit production facilities of F-35 Joint Strike Fighter & Eurofighter. People development for lean processes.
HJ BE RRY & SONS LTD KEY FACTS : ➔ ➔ ➔ ➔ ➔
Number of employees at site: 86. Family-owned business for the last 160 years (oldest furniture manufacturer in the country). All products are manufactured on site with no imported goods. All raw materials are from renewable resources. Probably the ‘greenest’ manufacturer in the UK, 8 environment awards received in 2008.
ISSUES TO BE DISCUSSED : ➔ ➔ ➔ ➔
General factory issues. Total quality management. Continuous Improvement programme. Chance to meet team leaders.
MAXIMUM DELEGATES : 30 ISSUES TO BE DISCUSSED : ➔ ➔ ➔ ➔
Business support for innovation and continuous improvement. Workplace organisation using 5S. People development. Engaging in total productive maintenance.
MAXIMUM DELEGATES: 30 ISSUES TO BE DISCUSSED : ➔ ➔ ➔ ➔
Developing the behaviour for lean improvements. Culture and change management. Continuous Improvement programme. Training and development across the enterprise.
MAXIMUM DELEGATES: 16 ISSUES TO BE DISCUSSED : ➔ ➔ ➔ ➔
Workplace culture. The benefits of using VSM to develop a structured action plan. 5S in factory and office environments. The lean transformation and plans for the future.
For details of all Factory Tours visit www.ukussummit.com TOUR SIZES: Tour group sizes are limited to between 10 and 40 delegates. Priority will be given to delegates who register early. SELECTING THE TOUR: The full list of factory tours will be available online and updated accordingly. Selection of tours will be based on a first come first served basis. For safety and security, only delegates travelling on tour coaches will be permitted entrance into the host site. Please contact customer services on 0800 458 9585 for all tour details and booking conditions, or visit www.ukussummit.com 16
NOTE: ➔ Safety shoes and suitable clothing may be required for particular tours, deleagtes registering will be given advanced notification of any safety items required. ➔ Some attendees may be precluded from participating in certain tours due to the nature of information released and some attendees may be required to sign a non-disclosure agreement before participating on a tour. ➔ All tours are subject to availability and require advance registration. Tour sites and/or content may be subject to change.
WEDNESDAY 10 TH JUNE 2OO9
NETWORKING SPECTACULAR For the latest information on tours and speakers visit www.ukussummit.com
The Summit provides unique opportunities to make contacts and cement new relationships and offers a multitude of ways to connect with current and future partners. Wednesday 10th June Drinks Networking Reception 17:15 to 19:30 The Manufacturing Institute is delighted to invite all delegates to an informal drinks reception at The Museum of Science & Industry, Air & Space Hall, just one hundred yards from the Summit venue. With complimentary drinks and canapĂŠs you will be able to speak to like minded professionals beneath the wings of fabulous flying machines.
Shingo Prize Award Ceremony During the evening we will also recognise the first UK challengers for the Shingo Prize for Operational Excellence. You will be able to meet and talk to those companies in the UK and Ireland who have embarked on the Shingo journey, as well as meeting the world-class speakers and organisations presenting at the summit.
Exclusive Tour of the Avro Shackleton Ever been inside a piece of aviation history? After the award ceremony you are free to walk around the Air and Space Hall and participate in an exclusive tour inside the Avro Shackleton.
Delegates have exclusive access to the Avro Shackleton during the Wednesday Networking Reception
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HOTEL BOOKING INFORMATION For the latest information on tours and speakers visit www. ukussummit.com
UK/US Shingo Summit – Towering Ambition Hilton Manchester Deansgate The venue for the 4th UK/US Summit is The Hilton Manchester Deansgate, located in the 47- storey Beetham Tower with commanding views of the City centre. The hotel’s popularity stems from more than just breathtaking views and a great location as guests enjoy the benefits of superb customer service within a contemporary environment and the pride of Hilton’s five star flagships.
Discounted Rates for Summit Delegates Accommodation has been pre-booked at significantly discounted rates for UK/US Shingo Summit delegates. Delegates can relax in 5-Star surround for just £99 per person per night including breakfast. This discounted rate is only available to bookings made through the UK/US Shingo Summit registration team and must be made by Friday 15th May 2009. After this rate bookings will be priced at £139 per person per night including breakfast. Please remember that the cost of hotel accommodation is not included in the summit fee. Before accommodation can be reserved at the rates published above delegates must be registered onto the UK/US Summit.
Location: The Hilton Manchester Deansgate is located 10 miles from Manchester Airport, with easy and quick access to Manchester Victoria and Piccadilly Train Stations.
There are three ways to reserve your room: 1) Telephone our summit booking line on 0800 917 1685 2) Complete the booking form and fax to +44 (0)161 448 2555 3) Visit www.ukussummit.com, follow the online joining instructions
DISCOUNTED DELEGATE RATE
£99
PER PERSON PER NIGHT
Manchester skyline photo courtesy of MEN Media
BOOKING BOOKING FORM FORM
Fax: +44 (0)161 448 2555 Or register by calling 0800 917 1685
ForFor thethe latest latest information information onon tours tours and and speakers speakers visit visit www.ukussummit.com www.ukussummit.com
Alternatively, please return this form to: The Manufacturing Institute, Quay West, Trafford Wharf Road, Manchester M17 1HH, UK Tel: 0800 917 1685 | Email: Info@ukussummit.com | Web: www.ukussummit.com
DELEGATE 1
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DELEGATE 2
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DELEGATE 3
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DELEGATE PACKAGES Qty.
3-Day Package 2-day UK/US Summit plus 1-day post summit tour
2-Day Summit Package Wednesday & Thursday UK/US Summit (tours can only be purchased with 2-day pass)
EARLY BIRD
LIST PRICE EARLY BIRD LIST PRICE
BOOK BEFORE 30TH APRIL
SME OFFER & PUBLIC SECTO R
SME OFFER & PUBLIC SECTOR
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Price Per delegate
BOOK BEFORE 30TH APRIL Price Per delegate
Price Per delegate
£620 + VAT
£770 + VAT
£495 + VAT
£620 + VAT
£495 + VAT
£595 + VAT
£395 + VAT
£495 + VAT
£295 + VAT
£395 + VAT
£295 + VAT
£395 + VAT
£600 + VAT
£600 + VAT
£600 + VAT
£600 + VAT
Boardroom One Day Pass Select from any of the days Criteria: Chairman, Managing Director: CEO or Board Member
Pre-Summit Shingo Workshop 2-day Shingo Approach Workshop
Hotel Accommodation The Hilton Manchester
Monday Evening
£99 per person per night including breakfast if registered with this booking form before Friday 15th May 2009. £139 per person per night including breakfast if booked after the 15th May 2009.
Tuesday Evening Wednesday Evening Thursday Evening
TOTAL Consultancy Rates: Capacity is limited at the summit and is designed for the sharing of best practice. Delegates from a commercial consultancy/advisory background is strictly limited and will be charged at £995 + VAT per person for a two day ticket only. There is a limit of two delegates from consultancies/advisory at the pre-summit workshop. Please contact Jon Tudor, Summit Director, on 0161 872 0393 for further details. SME/Public Sector Rates: SME’s are classified as organisations who employ less than 250 people and have a maximum turnover of £34m. If your company is part of a group, the collective headcount of the group, not the individual site, is taken into account. Public sector includes charities, armed forces and all emergency services. PLEASE SPECIFY ANY DIETARY OR ACCESS REQUIREMENTS
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Please note: The Manufacturing InstituteTM reserves the right to change the programme, speakers or venue and alter or cancel any published dates without liability. Data protection: Personal data is gathered in accordance with the Data Protection Act 1998. Your details may be passed to other associates and partners of The Manufacturing Institute who wish to communicate with you. If you do not wish to receive information regarding other Manufacturing Institute programmes and activities and that of its partners, please tick here. The Manufacturing Institute would like to keep you informed about future events which may be of interest. If you do not wish to receive these alerts please tick here. CANCELLATIONS: Should you be unable to attend, a substitute is always welcome at no extra charge. A full refund, less a service charge of 10%, is given for cancellations received in writing (letter or fax) four weeks prior to the conference. A 50% refund will be sent for cancellations received two weeks prior to the conference. Regrettably, no refunds can be made for cancellations received less than two weeks prior to the conference but a substitute delegate is always welcome. This document is printed on Green Coat Velvet which contains a percentage of recycled pulp.
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