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Presenter: Mike ElsholzCompany: Steelcase Inc.History: 25 years experience• Engineering• Project Management• Test Lab Supervisor• Model Shop Manager

Outside interests: family, golf, football, wood working.

Managing Projects and Work Flow

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VictorSteelcase's history of innovation and sustainability began 100 years ago with Victor, a metal wastebasket designed to reduce fires caused by ashes in wicker wastebaskets.

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• Business Strategy and Objective• Shop Layout• Strategy• Workflow

• Project Tracking• Use of a database

• Procedures and Safety

Presentation Outline based on my recent Model Shop

transformation/move

Questions are welcome

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Identify your business:• What do you do• Who are your customers• What is your focus• What is your core competencies (areas of

strength)• What is your work environment• Functional model vs. soft visual models

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Opportunity for ReinventionSteelcase CDC

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Opportunity for Reinvention Steelcase CDC

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Opportunity for Reinvention

We were planning to move out of CDC• Should the model shop move• Disband, move as is, move and

modify• Shop size (sq. footage) • Evaluated who we are

• What we wanted to be• Determined our strengths

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• An internal shop of a large Corporation• Support New Product Development• Our Customers are

• Engineers/Designers• Show rooms• Mock-ups for customers• Facilities• Sales• Other

Philosophy on Modeling• Build to learn• Build it, see it, touch it• Repetitive model builds• Visual and factual• Hands on modeling (design and engineering)

Who we are

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We Focused on our Capabilities core competencies

• Sheet metal• Upholstery• Wood• Painting• Welding• Assembly

other areas• Machining• CNC milling• 3D printing

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Outsourced Capabilities

• CNC milling• 3D printing• Casting• Molding; vacuum, injection, …

Model Shop Reinvention

Mission statement:An integral component of New Product Development that is a collaborating part of Design and Engineering thinking. Making design ideas tangible and assessable through quality modeling and providing hands on learning. A part of the building of intelligence in new product development. Designing and modeling on the edge of solvability.

Objectives: Build models collaboratively Providing input and feedback on product designs A source of knowledge Continuously improving turnaround time of prototypes, Excel Can do attitude (not limited) Easy to work with Problem solvers Versatile team with large skill set and experience Agile/Flexible

Principles A) Modeling makes Design thinking tangible and

assessable. A part of the building of intelligence in new product development.

B) Modeling as method for hands on learning is integral to New Product Development and the collaboration between Design and Engineering thinking.

C) Modeling is a means to defining the edge of solvability.

D) Modeling is a tool, as drawing is a tool, and requires immediate and dynamic accessibility.

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RECOMMENDATION: It is critical for New Product Development to have a Model Shop located in close proximity to PD&L where product development is being controlled and design decisions are being reviewed and made. The new Model Shop will have the appropriate capabilities and capacity to adequately support new product development. It needs to be staffed with talented, creative, forward thinking Model Makers that can work in a professional and collaborative environment that fosters creativity. These individuals must be able to interact and share ideas with co-workers, Designers and Engineers. The Environment needs to be conducive to creativity , learning and support a collaborative work space.

BENEFITS:•Improves PD&L development time lines through faster turnaround on prototyping builds.•Improves cycle time on learning cycles which improves PD&L intelligence.•Control of our design confidentiality and intellectual property•Improves the collaboration between the development teams and the Model Makers which provides better designs from increase learning .•Control over Priorities (i.e. “HOT” emergency jobs)

NEGATIVES:•Larger move cost (relative to a Basic Shop).•Larger utility and overhead cost (relative to a Basic Shop).

NOTES; Recommendation is based on analysis of our experiences of outsourcing and discussions with leaders with in PD&L (Engineering and Design Directors).

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Let’s look at our work flow

order

3D

machining

wood

assembly

Completion $$$

Work Flow

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Restructuring Work Flow & Layout

What is your work environment?

How do you work?Individually/independently

CollaborativeCreativeHands on

Teams

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The process we usedAnalyze your current layout

• Involve your Team• Analyze by area• What works well• What does not well• Wish list• Pros/Cons• Prioritize Requirements

how

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Work Flow and Shop LayoutSteelcase

Our focus was on collaboration and interaction (high to low)

High Office Benches and assembly area Sheet metal Upholstery WoodLow welding painting Machining Rapid Prototyping

new

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EngineeringDesignmarketing

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Welcome to our new home

Jan. 2014

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Repurposed an old plant

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Concept ShopRapid learnings

Hands on modelingDesigner and Engineering

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Project TrackingHow do you track your projects?

Use of work requests – mini formSpread sheetsElectronic vs. paper

What information do you want to track?CostTiming Status of projectsWork flowCompletion Reports

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DatabaseUse of a database can help track work

requests, cost, status of work, communication with customer and reports.

Assign work request to team leads or model makers

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DatabaseSteelcase

We currently are using MS Access as our data baseReadily availableBut has limitationsNeed some training

We are in the process of changing to SAPIt our company standardIt’s powerfulBut can be more than you needNeed training

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Current Database Back office

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Current request form

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Current Database

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New Database Criteria

Improve target areas: VisibilitycommunicationTrackingThrough putEase of filling out request, adding tasks, split orders

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New Database Criteriaadding tasks and split orders

request

Model maker

Sheet metal

Model

maker 2

outsource

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New Database CriteriaWork Order/ Request

Generate unique number per work order Our work instructions Require: Name, Phone and email Date Needed Cost Center#, WBS# Cost Center Owner Back up Person and Phone# Cost Estimate requested (auto email back to requester) Work Instructions (similar to current)

Wood Sheet Metal (s/m) 3D Printing General Model Making

Drawings/Prints, Data files linked to WO to include Rev. level Easy work request creation (Auto Population) of new WO and for add on

i.e. Button on original WO that uses pertinent information (use of an extension or new request number)

Auto Message (email) as to which Model Maker was assigned Auto Message (email) when Work Order completed Bar code generated and assigned to each W.O. for tracking purposes

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New Database CriteriaDatabase Requirements

Houses Work Order IP ProtectionStorage (Data, Prints) 5 yearsAttach and store prints and picturesScanned PDFLegacy Data Base

Keep? How long? Where? Or convert to our New Database

Cross Charge/Finance Team (SAP) Track labor hours and cross charge each month to Cost Center & WBS Track material costs and cross charge each month to Cost Center &WBS Track outsourced costs and cross charge each month to Cost Center & WBS

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New Database CriteriaTracking: Through Shop/Process/Department

What do we Track, (outsource, split order, Process Paint, Weld, Laser, % completed, who is currently working on it) Auto email sent to requester each time the status is updated. % complete is updated each day

How do we track it (Scan Bar?) scanner throughout the shopModel Maker notes and activity of project captured on Work

Order(story)Who sees it (Transparency, Process, on Touch Screen) i.e..

Requester, Model Maker, Cost Center ownerTie Purchase Orders to Work OrdersTime/hours work on each job (similar to today)

Need to output to Finance

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New Database CriteriaReports

Cost by Requester , Person, Cost Center, WBS#, Supplier, In-house, Outsource, and Project Name (Same as Today)

We Want Monthly Reports on (General Performance) Number or requests On Time Outsourced Cost to (Requester/Model Shop/Hours) Quality Jobs on the Floor Projects

Is every WBS# and Cost Center in SAP?Controlling Data/Reports vs. open to all?

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Procedures and SafetySet safety procedure and policy

Overall shopEach machineConsequences for not following

JSA Safe machine operation

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JSA – Job Safety Analysis

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Safe use policy