Composite_Age_Summer_2009_Final

8/7/2019 Composite_Age_Summer_2009_Final

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Molded Fiber Glass Companies

Composites Age | Spring/Summer 200

SPRING/SUMMER 2009

From Lean to GreenWaste Stream Investigation and Lean Practices SupportMFGs Commitment to Environmental Responsibility

Lean manuacturing is a cultural hallmark at Molded Fiber Glass Companies.eammates are on alert 24/7 to uncover new ways to reduce costs that do not addvalue to the end product or customer satisaction.

In 2008, MFG took Lean a step artherinto the realm o Green with amandate to examine the waste stream o all operations in light o environmentalimpact. An internal program was created to apply the Lean disciplines to energyeciency, waste reduction, and compliance with environmental regulations.

Led by teammates Matt Narducci and Perry Bennett, the new program started

with an assignment to identiy and chart waste stream projects. Te consolidatedndings provide a baseline or the soon-to-be-released corporate MFG BestGreen Practices which covers all types o waste and outline options, examples,and tips or getting greener. Results will be monitored over time to supportcontinuous improvement.

O the many notable Lean Green projects that are happening at MFG, the ollowing cases are interesting eforts that showwhat creative thinking and team vision can achieve.

MFG Tray is addressing environmental impact inlarge and small ways. o reduce energy usage they enrolledin a two-part program called EnerNOC (Energy NetworkOperations Center). Te rst part is the Emergency LoadResponse Program that provides nancial incentives or peakperiod electricity reduction. Ater researching the experienceso other participants, the MFG team determined this was asmart move. Part two involves installation o an EnerNOCSite Server (ESS) at the actory. Tis monitoring systemprovides detailed usage datareal-time power metering,data collection, data communication, reports and analyt icsenabling improved planning and decision-making.

CEO Richard Morrison works with Matt Narducci(Corporate Safety Manager) and Perry Bennett (Corpora

Health, Safety and Environmental Director) to developthe Lean Green program, MFGs corporate-widemandate to pursue improvements to the waste stream.

MFG ray teammates LaZica Charbonerau and BillStewart demonstrate the new shredder that perforatescardboard into packaging material. Boxes from incoming

material now cushion the products going out the door.

Continueson next page


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he 2009 ACMA COMPOSIES+POLYCON convention

in February brought together more than 180 exhibitors and2,500 industry proessionals. Each year the most innovativeproducts and accomplishments are presented or peer reviewand recognized with ACE and Pinnacle Awards.

his year, the Process Innovation Award went to MoldedFiber Glass Companies (MFG CSC) or its 2009 Pontiac Solstice Coupe Rear Floor

Assembly (trunk). his product demonstrated innovation in manuacturing methodsthat increase production rate and volume while maintaining quality. he one-piececompression-molded composite trunk provides storage, attachment points or bodypanels, hardware attachments or electrical components and air ducts. It was producedusing proprietary nano technology to achieve a special SMC with a speciic gravity o1.5. Because its made rom composite, the trunk is corrosion resistant, an important

eature or the underside o the vehicle.Many teammates at MFG Corporate, MFG Design and MFG CSC are behind this

accomplishmentcongratulations and thank you to everyone that played a part!

On another ront, Richard Morrison, CEO o MFG was recognized with the ACMAPresidents Award or his 40+ years o contributions and leadership to the compositesindustry. Presenting the award to Richard was John ickle, ACMA president. Sincemeeting Richard in 1972, Ive been impressed with his unailing commitment to sup-porting the interests o the composites industry, said ickle. Over these years, he andhis company have contributed signiicant unds, expertise and time supporting our asso-ciations activities, rom sponsorships and technical papers to employee participation.

For 40+ years of contributions and leadership to the composites

industry, Richard Morrison, CEO of MFG received the2009 Presidents Award from ACMA President John ickle.

ACMA Ace AwardGoes to MFGfor Solstice Coupe

Te 2009 ACE Award for Process Innovation

went to MFG for demonstrating innovationin manufacturing methods with the PontiacSolstice Coupe Rear Floor Assembly (trunk).


From Lean to Green Continued from coverIts too soon to know what the annual energy savings will be, but the 2009

nancial impact, including incentives, will be in excess o $23,000.

MFG ray teammates a lso ound a use or waste cardboard that accomplishesall 3Rs (reduce, recycle and reuse) in one smooth move. Although recycling

waste cardboard has been in place or 10+ years, a shredder was discovered that

perorates sheets into usable packaging material. Cardboard rom incomingmaterial now cushions the products going out the door. Tis helps the recyclingefort, eliminates the expense o plastic bubbles, and reduces overall waste!

MFG alabaMa

Dissatised with the quality o service and cost o their reuse removal service,teammates at MFG Alabama went straight to the bottom lineliterally. Withno alternate supplier to turn to, the investigative teammates took a hard look at

what was going into the dumpsters, and why. Teir ndings suggested that ithe entire company could be engaged, there was an opportunity to signicantlyimpact the waste streamsaving both the Earths and MFG resources.

MFG Alabama found a way to eliminate use of aerosoladhesive from one production processes, eliminatingthe cans, the adhesive and the propellanta very

positive change for the environment! Assemblyteammates Sherril Berry, Lynn Vann, Byron McClainand Joey Clark are involved with this new process.


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Governor Mike RoundsVisits Aberdeen

Starting a green ield manuacturing plant is no easy task. hanks

to the good eorts o MFG South Dakota teammates, the Aberdeencommunity, and the state o South Dakota, MFG has made prog-ress in creating a irst class wind blade production acility. GovernorRounds recently toured the entity to express continuing support andencouragement, and to congratulate MFG on completion o the100th blade.

he South Dakota Chamber o Commerce and Industry recentlylauded MFG SD with one o our 2009 ABEX awards or busi-ness excellence. ABEX awards are given annually in conjunction

with the Governors Giant Vision Business Plan Awards. MFG SDreceived the outstanding New Kid on the Block award, recognizinga company that has been in existence less than 3 years. Blake Seas,general manager o MFG SD, accepted the award.

Governor Mike Rounds paid a visit to congratulate MFGSouth Dakota on rolling out the 100th blade! eammates hada great opportunity to talk directly with the governor.

Blake Seas, general manager of MFG SD,accepted the 2009 ABEX award for businessexcellence from Governor Mike Rounds.

Te rst item was cardboard. Followinga unique course, teammates purchased

an inexpensive trailer and persuaded theCity o Opp to make a weekly recyclingpickup, returning the trailer empty. Otherobjects identied in the dumpster includeditems that were candidates or government,commercial or supplier recycling programs,including paper, scrap plain steel, stainlesssteel and knie blades.

Te disposal o wood pallets wasapproached rom both consumption anddisposal angles. Ways were uncovered toreduce in-bound material, automatically

reducing the stockpile. On the disposal side,many creative ideas suraced: some suppliers

agreed to retrieve their pallets; truckingoutts were invited to take what they coulduse or ree; some were ofered to teammatesor home heating.

Another nd in the dumpsterboxeso discarded gun roving roll-ends. One

week o accumulation was a signicantamount o material, so shit leaders startedhelping teammates utilize each roll to theend. Meanwhile, alternate packaging withcontinuous-use rolls was sourced, eliminatingroll-ends rom the dumpster completely.

Probing into processes, teammatdiscovered a way to eliminate scrap trimmin

and paper waste by converting several smaparts rom hand lay-up/spray-up to SMparts procured rom MFG CSC (at a cosavings)! Buckets or transporting resin tpoint o use were eliminated by installinbulk resin tanks and permanent piping tmolds. And aerosol cansa menace to aquality and landllwere eliminated wita process improvement that involves simpcleaning the surace and using weighterollers or application.

In the last issue o Composites Age it was reported that teammates celebratedshipment o the irst wind energy blade. Months later, Governor Rounds paid avisit to congratulate the team on rolling out the 100th blade! his accomplish-ment was possible through the extreme dedication and hard work o manyteammates throughout the Molded Fiber Glass Companies. Many teammatesrom other entities accepted tours o duty to Aberdeen to train, problem-solve,and otherwise contribute their skills and knowledge to get this new entity oto a successul start. hanks to al l!

printed on recycled paper


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GE Honors MFG with Supplier Excellence Award

Standingor Excellence

On March 10, GE Champion Carl LaFrance accepted theprestigious GE Excellence in Lean award on behal o MFG.he awards ceremony was held in Atlanta, GA in conjunction

with GE Energys supplier conerence. his award is presentedyearly to one selected supplier or outstanding perormance incompliance, quality, lean, direct material productivity, growthand customer-centricity.

MFG has consistently demonstrated a commitment to excel-lence, said Jody Markpoulos, vice president o global sourcing, GEEnergy. GEs Excellence in Lean award recognizes the companysdedication to integrity, strong values and quality perormance.

In addition to the beautiul trophy, GE will und a wall muralpainted by the Foundation or Hospital Art volunteers to bedisplayed at the Ashtabula County Medical Center. Since 1984

the non-proit Foundation or Hospital Art has created 30,000+ public works o art atmore than 2,000 hospitals in 190 countries.

Award honorees were selected rom a ield o 60 US and European contenders nomi-nated by GE global commodity leaders and supplier quality leaders. Applications werevetted through a rigorous selection process by GE Energys senior sourcing leadershipteam, and inal decisions were based on quantitative metrics and subjective opiniontied to historical relations.

Wind Energy Service celebrated both their irst ull yearin business and the remarkable eat o one ull year withouta single injury. eammates at WES ind themselves in sometrecherous positions repairing wind energy equipment through-out the country. Great going, teamwe wish you another yearo accident-ree adventures.


MilestonesWES: Accident-Free Zone

Six Sigma Green BeltMiran Vegel, Corporate Auditor receivincertifcate rom MFG Sr. VP Joe Wilk.

MFG Union City Service AwardsJackie Skarzenski, 35 years

Pat Malec, 20 years

MFG Alabama Service AwardMike Gill, 10 years

Quality/Process/Tooling Manager

(with Plant Manager Mike Leonard)

MFG South DakotaBlake Seas,

General Manager

TeammateApplause

Achievements andNew Arrivals

Composite_Age_Summer_2009_Final

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