The document discusses Sam Wagner's role leading advanced manufacturing at Donnelly Custom Manufacturing and implementing Lean and TWI programs. It describes how Donnelly used a mistake-proofing workshop based on TWI principles to significantly reduce defects and external costs of quality, improving from good to great performance. The workshop focused on identifying and eliminating root causes of mistakes through a structured approach and mindset changes.
2. www.donnmfg.com Sam Wagner, Director of Advanced Manufacturing [email_address] 320-762-6408 As the Director of Advanced Manufacturing at Donnelly Custom Manufacturing Company in Alexandria, MN, Sam Wagner leads the production, quality, process engineering, training and continuous How Short Run is Done™ improvement functions. In this role, he is responsible for the identification, assessment and implementation of advanced technologies and process improvements that continue to adapt and advance Donnelly’s short-run expertise. He has been closely involved with implementations of information technologies, Lean manufacturing techniques, quality systems and automation. He holds an MBA from San Diego State University and BS in Engineering Management from the University of North Dakota, and is a Certified Trainer in TWI’s Job Methods. Mr. Wagner’s experience includes executive, management and engineering positions in both high and low volume production of plastic and metal products in a variety of industries including defense and aerospace, agriculture, construction and transportation.
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7. Job Relations (+JI&JM+) Benefit Industry Average: 34.4%* Successful Co’s: 25.6%* * Ref: Plante & Moran 2009 Report of 179 N. American plastics processors (60% injection molders) running 265 separate facilities, as reported in Plastics News , Feb. 25, 2010 Enabling Technology
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10. Bottom Line Results 15 years without increasing press rates And increasing services While decreasing setup prices
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12. So let’s go find a problem! Sherlock Holmes (Sidney Paget, 1904)
13. Total Cost of Quality Performance (For Calendar Years) % of Sales Quality Performance Good, But improvement slowed Standard for external cost of quality ISO TWI Lean
16. Quality Performance (one part #) Mistake One mistake on one box = March PPM of 1,341vs. Customer expectation = 500 Good parts Rejects
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27. Total Cost of Quality Performance (For Calendar Years) % of Sales Quality Performance Good, and improving again Standard * YTD through March ISO TWI Lean
![www.donnmfg.com Sam Wagner, Director of Advanced Manufacturing [email_address] 320-762-6408 As the Director of Advanced Manufacturing at Donnelly Custom Manufacturing Company in Alexandria, MN, Sam Wagner leads the production, quality, process engineering, training and continuous How Short Run is Done™ improvement functions. In this role, he is responsible for the identification, assessment and implementation of advanced technologies and process improvements that continue to adapt and advance Donnelly’s short-run expertise. He has been closely involved with implementations of information technologies, Lean manufacturing techniques, quality systems and automation. He holds an MBA from San Diego State University and BS in Engineering Management from the University of North Dakota, and is a Certified Trainer in TWI’s Job Methods. Mr. Wagner’s experience includes executive, management and engineering positions in both high and low volume production of plastic and metal products in a variety of industries including defense and aerospace, agriculture, construction and transportation.](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)