Edison Site Visit Presentation
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Transcript of Edison Site Visit Presentation
Edison, New Jersey – Site VisitSeptember 2016
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DRAFT
Agenda
1. Edison, NJ Introduction and Facility Overview
2. Site Capabilities, Markets, and Customers
3. Performance and Financial Information
4. Plant Tour
5. Q&A
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Edison, NJ Introduction and Facility Overview
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DRAFT
IntroductionLocation Facility
Product lines Solar shade window management systems.
Functions Custom product fabrication.
ProcessesFabric cutting, shade and bracket assembly, electrical component assembly, testing, and programming.
Leased / Owned Leased
Annual Lease Expense $324,000
Lease End 4 / 2025
Shifts (Current/Max) 2 / 3
Capacity Util. % 67% in 2016 / 67% in 2021
Sq. Ft. (‘000) 72# Employees 156
Key Facts
Edison, NJ
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MechoSystems East - 8 Sutton Pl. Edison, New Jersey 08817Tel: +1 (732) 339-0751
DRAFT
Site History
Edison, New Jersey facility was leased and began operations in 2004.
Major product line expansions since 2004 include: Trapezoidal Shades (2006) First programmable motors (2006) SolarTrac (2007) Monumental Shades (2008) Sundialer (2009) IQ1 Std. Intelligent motors (2010) MagnaShade (2013) IQ2 Intelligent Programmable motors (2013) ShadeLoc (2014) Mecho Network Interface Controller (2015) Day Light Sensor Controller (2016) Mechonet Wireless Controller (2016)
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Shade Fabrication Area
Fabric Cutting Area
DRAFT
Site Organization Chart
Winnie YuHR Manager
Tony LamDirector of Finance
Continuous Improvement & Engineering
Manager[Open]
Arlana FlynnSenior Buyer
Indirect Responsibility, Dual Reporting Direct Responsibility
Manufacturing hourly 114Warehouse hourly 12Operations / Office hourly 6TemporaryEngineering
101
IT 1HR 1OtherGrand Total
11156
Mark LangitQA Engineer
Maintenance Supervisor[Open]
Brian KeenanPlant Manager
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Heidy BocanegraShipping Supervisor
Johanny BritesHaydee CarhuaricraProduction Supervisors
DRAFT
MechoSystems Edison, NJ: Fabrication Floor
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DRAFT
MechoSystems Edison, NJ: Office Area
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DRAFT
EquipmentHempocket/Splining (3)
Miller Weldmaster 112 ExtremeMoving head, hot-air spline welder.
Matic Ares-6000Spline and hempocket impulse welder.
Future Equipment ProjectsIncreased racking capacity.
Pick to Light systems.
Frontier Enterprise Resource Planning system.
Advanced riveting and automatic crimper/stripper machines to support bracket and cable assembly capacity increase.
Fabric cutting capacity increase.
Aeronaut - Fabric CutterCrush and Ultrasonic cutting capabilities.
Advanced cutting optimization – camera / optical mapping.
Fabric Cutting (4)
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Aeronaut Fabric Cutter
Matic Ares-6000 Miller Weldmaster
DRAFT
Workforce
Total Number of Employees 156
Percentage Split of Permanent/Temps 93.6% / 6.4%
Turnover 4.27%
Safety (Recordable/Lost Time Rates) 2.67% / 0.00%
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Site Capabilities, Markets, and Customers
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DRAFT
Capabilities Fabricates highly engineered window management systems.
Specializes in hard-to-solve design and technical challenges, such as the shading of non-rectangular, sloping, high, wide, monumental, difficult-to-access, and other nonstandard windows.
Ability to fabricate motorized shades with widths ranging from two feet to forty feet.
Ability to produce 7000 bands per week or 350,000 bands per year.
Fabricates image shades with customer supplied fabric.
Capability to fabricate electrical controllers such as the Sundialer, Mechonet Wireless, Daylight Sensors, and Radiometers.
Operates a standard two shift (16 hours per day) operation with the flexibility to scale up to a twenty hour work day within an eight hour notice.
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Monumental Multi-Banded Image Shade
MagnaShade installation at the Whitney Museum, New York City, NY in 2015.
Performance and Financial Information
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DRAFT
Continuous Improvement
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Manufacturing Optimization Initiatives: Q4/2016 – $112.5k; 2017 – $1.16mm; 2018 – $1.31mm; 2019 – $1.31mm Transfer manual single banded solar shade fabrication from Edison to Reynosa – Status: On going. Consolidate specialized highly engineered products from Phoenix to Edison – Status: Start 11/2016.
Advanced Manufacturing Initiatives: Q4/2016 – $59.1k; 2017 – $247.6k; 2018 – $256.3k; 2019 – $256.3k Enterprise Resource Planning system – Frontier and SAMS – Status: On going, projected completion date of 3/2017. Machine integration with SAMS – TigerStop systems – Status: Projected completion date of 3/2017 Implementation of Pick to Light systems for bracket and tube assembly areas – Projected completion date of 3/2017. Laser guided, moving head hot-air spliner machine – Miller Extreme 112 – Status: Completed 9/2016. Dual function, impulse welding hempocket/spliner machine – Matic Ares-6000 – Status: Completed 9/2016.
Springs Business System - Lean Implementation through Employee Engagement Q4/2016 – $25k; 2017 - $100k; 2018 – $100k; 2019 – $100k KPI charts maintained and reviewed on a weekly basis – Status: On going. 6S initiatives in 2016 designed to improve fabrication process flow and pedestrian safety – Status: On going. Work instructions available for major processes – Status: On going, projected completion date 1/2017. Gemba walks conducted each morning by management team – Status: On going.
Quality at the Source - Process Controls: Q4/2016 – $25k; 2017 – $100k; 2018 – $100k; 2019 – $100k Incoming inspection of raw materials such as fabric, aluminum extrusion, and injection molding – Status: On going. In process defect and dimensional inspection after panel cutting – Status: On going. WIP inspection of shades and brackets – Status: On going. Implemented weekly meetings with Shade Shop associates to review quality issues and corrective actions. Revised fabric sample books for the fabric cutting associates – Status: On going. Provided associates training to refine skills for reading work orders – Status: On going.
Results: Installed wider hempocket machine (Matic Ares-6000) to reduce cycle time and improve productivity. Installed 30’ long, moving head hot-air welding machine (Miller Extreme 112) to reduce cycle time and improve productivity by limiting the need for
Kabar technology. Advanced riveting and automatic crimper/stripper machines to support bracket and cable assembly capacity increase. Continuous Improvement projects for 2018 to 2021 will offset target wage inflation rate of 3% per year or $97,350.
DRAFT
Key Performance Indicators
YTD month incident rate (TCIR) 2.67%
YTD recordable rate 2.67%
Corporate safety audit 28.96%
Percent complete on company training 92%
Safety
Plant Productivity 39.4 MPB
% OT 10.9%
Turnover 4.27%
Var. expense per unit (ATO) $ 84.17
Quality
Internal Quality Audits 95.62%
RMFG 2.49%
RSHIP 0.44%
PMFG 0.69%
FPY 99.08%
DPPM for components
Costs
OPD 97.01%
Carrier Performance
FedEx 98.63%LTL 72.96%
Delivery
All aspects of manufacturing tracked to goals
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2016 YTD (Aug)
DRAFT
Key Performance Indicators (cont’d) - A
Safety – Recordable Rate
Delivery - OPD
Initial Quality
Productivity – Minutes Per Band
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2014 2015 2016 YTD Aug02468
1012141618 17.12
2 2.67
1.64 1.52 1.27
Edison SWF
2015 2016 YTD Aug0
0.5
1
1.5
2
2.5
3
2.682.49
2.07 1.94
Edison SWF
2015 2016 YTD Aug75.00%
80.00%
85.00%
90.00%
95.00%
100.00%
89.10%
97.01%
84.07%
91.26%
Series1 Series2 2014 2015 2016 YTD Aug35
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3738
3940
41
4243
4445
44.5
38.839.4
DRAFT
Financials
Sales
Units
CAPEX
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($’000)
($’000)
2011A 2012A 2013A 2014A 2015A 2016 YTD Aug$0
$20,000
$40,000
$60,000
$80,000
$43,686 $50,051 $51,708 $54,345 $58,013$41,585
2011A 2012A 2013A 2014A 2015A 2016 YTD Aug0
50,000100,000150,000200,000250,000300,000350,000
196,720
252,872286,350 289,118
318,403
233,839
2011A 2012A 2013A 2014A 2015A 2016 YTD Aug$0
$200
$400
$600
$100 $128 $176
$505
$92$227
Plant Tour
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DRAFT
Introduction to the Site Plant Tour
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DRAFT
Important Safety Information
Safety glasses should be worn at all times in designated areas.
Hearing protection required in designated areas.
Only walk in designated area unless accompanied.
Obey all warning signs and follow the host’s instructions.
Do not touch moving or rotating parts of the machines.
Smoking is prohibited except in designated areas.
No food or drink allowed on floor.
Camcorders, photo cameras, recording devices, and cellular phones may not be used without prior permission.
In case of emergency, please follow your host’s instructions and vacate the area using the evacuation routes.
Do not pick up or touch products.
Ensure to sign out prior to leaving premises.
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Thank You!
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