Professional Documents
Culture Documents
inside littelfuse
A BRAND BUILT ON EXPERTISE IT ALL STARTS WITH YOU
in this issue:
Feature Articles
1 2 3 3 4 4 5 Teams Drive Lean Enterprise Tech Center Opening in Research Park Associates Embark on Lean Master Journey Simplifying Business for Profitability Wuxi Wafer Fabrication Goes Live Global Engineering for ASBU Growth Lean Office Helps LFKK Save Time
Associate Relations
5 6 6 7 7 7 8 Lean Benchmarking at Steelcase Pitch Boards Update Lean Progress Matamoros Supports Silicon Transfers One Associates Contribution to Lean Dongguan Streamlines Varistor Production Teams Streamline Order-to-Cash Lean Benchmarking at Littelfuse
Customer Relations
8 Custom MOV Leads to New Business 9 Fusebox Opens Door to OTB Business 9 New POWR-GARD Services Website
and Tom Novak have completed Lean Office training in their journey to become Lean Masters (see story, page 3)
n To benchmark and learn from other organizations,
Lean will make Littelfuse a faster, more responsive and customer-focused organization. While it doesnt happen overnight, weve already made good progress. Ryan Stafford, Executive Sponsor of Littelfuses Lean Enterprise
Littelfuse team members recently visited Pella Corporation, a company known for extremely high customer satisfaction, and Steelcase, a recognized leader in Lean Enterprise (see story, page 5)
continued on page 2
of hours of time and allowing associates to work on other projects (see LFKK story, page 5)
n Lean Office Value Stream Mapping and Kaizen Events are helping
associates such as Credit Analyst Deneen Johnston learn how to drive waste out of their work areas (see story, page 7)
n Now underway are Kaizen events tightly focused on four key areas to
improve Littelfuses order-to-cash process (see story, page 7) Read this issue to find out more about these and other initiatives. If you take the order-to-cash analysis and multiply the savings in time by the number of opportunities throughout Littelfuse, you can see that Lean is a very powerful tool that can help drive our future success, said Gordon. Ryan agreed, adding, While many companies try to implement Lean, very few succeed. It takes persistence, attitude and endurance. If we are successful, it will not only improve our financial performance but ensure better, more challenging opportunities for our entire workforce.n
LEAN Enterprise Develop a companywide culture focused on improving processes and reducing waste, increasing efficiency and customer responsiveness.
Actions taken to appropriately size our business have put us in a much healthier situation. Paul Dickinson, leader of Littelfuses profitability initiative
ness in Asia, and greater sales this year due to POWR-GARDs acquisition of Startco. These factors have resulted in the company raising its second and third quarter sales estimates above expectations. Despite this being a challenging time, everyone has handled themselves very professionally, said Paul Giagnorio. Paul Dickinson agreed, adding, As always, we want to thank associates for their hard work and dedication, which will enable us to achieve our goal of sustainable profitability. n
INSIDE LITTELFUSE | 3
Having application testing, project management, concept design and other engineering activities in proximity to customers design-in and decision-making locations is vital to Littelfuses future Juergen Scheele , Director, ASBU Product and Technology Development
Customers benefit by having application engineers, application labs, project management and concept design who are in the same time zone, speak the same language and share the same culture, he added. n
Commemorative wafers from the first production run at Wuxis new facility have been encased for display at facilities worldwide.
| FALL 2009 4
LEAN OFFICE SIMULATION HELPS LFKK SAVE OVER 200 HOURS OF TIME
Lean Office simulations have been underway worldwide, helping associates learn how to apply Lean concepts to non-production areas. Lean Office simulation enables participants to experience an actual Kaizen event in which ideas for making improvements are identified, decisions made, small groups established and implementation completed within a strict time period. One of the first sites to undergo training was the LFKK (Japan) facility, where associates faced a major challenge streamlining Inside Sales and Customer Service so that both functions could be handled in less time without impacting service or responsiveness. That meant we had to find 218 extra hours of time each month, said Global Inside Sales Director Ron Hess, who led a team of associates including LFKK General Manager Yoshiki Fujino; Office Manager Sumi Owada; Inside Sales/Customer Service Associates Kiyoko Horiuchi, Megumi Kujirai, Aki Nishino, Reiko Sato, Fumiko Akimoto, Istuko Otake, Joe Ng and Liang Yan; and Singapore Office Manager Karen Ong. Working together, the team determined that two activities Order Processing and Pricing, and Sample Request Processing were the leading pareto items accounting for 80% of associates time. After using Value Stream Mapping to define the current state of both processes, they applied Lean concepts to redesign them and created an implementation plan for executing these actions. Value Stream Mapping also helped the team identify five major Kaizen events that, when completed, will save over 250 hours of wasted time per month, reduce sample lead time by over 75%, optimize the sample warehouse and improve cycle times by more than 80%. With implementation underway, team members are pleased with their efforts. Until we looked at the entire Value Stream, I never realized how wasteful the process has been and how dissatisfied the customers were. While changing processes is challenging, it is exciting at the same time, said Aki. What I found most amazing was that none of the original ideas suggested at our initial meeting was used to fix the root cause. Problem solving is a process and the most powerful way to find solutions is by applying LF6 and Lean Tools, said Sumi. The entire team was highly engaged and interactive, added Lean Champion Dennis Craig. Management not only provided resources but participated in training and all VSM/Kaizen events. n
Signs display ideas, action items and value stream maps created by LFKK and Singapore Inside Sales/Customer Service associates during their recent Lean Office simulation. The Littelfuse Management Team met with Lean Team members at Steelcase this spring.
INSIDE LITTELFUSE | 5
Teams in each SBU are using the pitch boards in daily morning meetings to review whats happening and why, go over root causes and come up with solutions.
Process improvements made by Matamoros Engineering Section Leader Luis Raul Ramirez are being transferred to the Wuxi facility along with the products for which they were developed.
| FALL 2009 6
Dongguans
INSIDE LITTELFUSE | 7
Littelfuse recently shared its Lean initiatives with executives from industry-leading companies.
A custom MOV unit has opened the door to potential new business for POWR-GARD in the lucrative LED streetlight market.
| FALL 2009 8
This was the first time that the team participated in the global competition, surpassing 27 other finalists. This recognition is important, not just for the sake of winning the Silver Award, but because it points to how the team significantly increased production efficiency and, consequently, our business opportunities, said Asia Operations Director Dan Onken. This team not only fixed the problem, they fixed the root cause, said Lean Champion Dennis Craig, noting that the competitions lead judge was overwhelmed by the enthusiasm of the Littelfuse team. Weve experienced a major cultural shift, set new goals and brought in tools like Six Sigma and Lean to accomplish them. As a result, were improving inventory turns and delivery, reducing scrap and customer defects and generating increasingly better lead times, added Dave Heinzmann, Vice President Global Operations. n
| FALL 2009 10
solar applications. The characteristics and environment of PV systems may be significantly different than what most electrical designers are accustomed to, added Dan. We want this audience to know that we have the expertise and solutions they need. n
and value-added benefits. They not only protect workers from unsafe conditions, but result in significant cost-savings by reducing maintenance time, process downtime and motor repairs, said Tony Locker, Product Manager, POWR-GARD Protection Relay Products. Also available are feeder protection relays and supplemental monitoring products. All are being supported by POWR-GARDs new Ask the Expert online service, with engineers responding to customers technical questions within 24 hours. The comprehensive line is the result of POWRGARDs 2008 acquisitions of K-tec Corporation, a company specializing in innovative ground fault circuit protection technology, and Startco Engineering, Ltd., a major supplier of ground fault as well as motor protection and feeder protection products. By introducing this line, weve made major strides in our overall strategy of providing customers with the broadest range of electrical safety products available in the industry, added Tony. n
INSIDE LITTELFUSE | 11
Littelfuse POWR-GARD Services provides a broad selection of on-site and online Electrical Safety Training courses designed to increase safety and help your facility meet requirements of OSHA, NFPA and CSA standards. For a complete listing of Electrical Safety Training courses, visit www.littelfuse.com/services. Littelfuse POWR-GARD Services provides a broad selection of on-site and online Safety Training courses designed to increase safety and help your facility meet industry requirements. For complete listings of Training courses, visit www.littelfuse.com/services.
COURSE PGS405
Overview and Changes to NFPA 70E 2009 Safety Requirements DURATION: 2-4 Hours LEVEL: Intermediate ATTENDANCE: Electricians Engineers & Electrical Contractors Maintenance Personnel Supervisors & Safety Managers Qualified Workers
COURSE OSH101
OSHA 10 HR General Industry Safety Training DURATION: 10 Hours (1-2 Days) LEVEL: Introductory ATTENDANCE: Maintenance Workers Contractor Personnel Supervisors Safety Managers
DESCRIPTION: Most states and government agencies require contractors who perform construction or maintenance services on public buildings and facilities to employ workers who have attended an authorized 10 hour OSHA safety training class. Employees must be able to identify workplace hazards and use safe work practices and protective equipment if exposed to the hazards. Workers must have received a certified 10 hour card from OSHA. Some industrial and commercial general contractors and owners also require sub-contractors to train or employ workers who have received 10 hour OSHA safety training. Littelfuse Course OSH101 is taught by an OSHA General Industry outreach trainer authorized to issue 10 hour OSHA certification cards to those who successfully complete the 10 hour program. OSHA 29 CFR 1910 General Industry standards are reviewed and studied. TOPICS INCLUDE: Introduction to OSHA, Employer and employee rights and responsibilities OSHA inspections, Citations, and Penalties Fall protection, walking, and working surface safety (Subpart D) Exit routes, Emergency Action Plans, and Fire Protection Plans (Subparts E and L) Introduction to Electrical safety (Subpart S) Hazard Awareness and Communication requirements (Subpart Z) Personal Protective Equipment (Subpart I) Hazardous Materials (Subpart H) Materials Handling (Subpart N) DELIVERABLES: PowerPoint presentation Workbook and classroom exercises Handout materials
DESCRIPTION: This course focuses on previous and new requirements of NFPA 70E, Standard for Electrical Safety in the Workplace. An overview of the standard and its requirements will be presented with special attention to changes in the new 2009 Edition of NFPA 70E. TOPICS INCLUDE: Who is covered by NFPA 70E Employee Training Requirements Arc-Flash Hazard Calculations NFPA 70E Table Method Equipment Warning Label Requirements
Littelfuse POWR-GARD Services provides a broad selection of on-site and online Electrical Safety Training courses designed to increase safety and help your facility meet requirements of OSHA, NFPA and CSA standards. For a complete listing of Electrical DELIVERABLES: Safety Training courses, visit www.littelfuse.com/services. PowerPoint presentation Handout materials Participants may receive Littelfuse CEU credit after passing an Electrical Safety Quiz COURSE PGS406 DESCRIPTION: Overview of CSA-Z462 This course focuses on the requirements of Canadian Standard CSA-Z462, Standard on Workplace Electrical DURATION: Safety. An overview of the standard and its requirements 2-4 Hours will be presented along with how this standard was developed to be in parallel with NFPA 70E. LEVEL: Intermediate ATTENDANCE: Electricians Engineers & Electrical Contractors TOPICS INCLUDE: Who is covered by CSA-Z462 Basic Requirements Arc-Flash Hazard Calculations Z462 Table Method Equipment Warning Label Requirements DELIVERABLES: PowerPoint presentation Handout materials Participants may receive Littelfuse CEU credit after passing an Electrical Safety Quiz
Littelfuse POWR-GARD Services Maintenance Personnel 8755 W. Higgins Rd, Suite 500 Supervisors & Safety Managers Chicago, IL 60631 Qualified Workers www.littelfuse.com/services
Littelfuse POWR-GARD Services 8755 W. Higgins Rd, Suite 500 Chicago, IL 60631 www.littelfuse.com/services
Littelfuse POWR-GARD Services 8755 W. Higgins Rd, Suite 500 Chicago, IL 60631 www.littelfuse.com/services
In just a few years, POWR-GARD Services Electrical Safety Trainers have helped thousands of electricians, plant managers, engineers and maintenance workers throughout North America learn how to identify Arc-Flash hazards and ensure safe electrical practices in the workplace. That number is sure to increase, thanks to five additional electrical safety training modules that will enable companies to comply with the latest industry requirements, generating greater attention for POWR-GARD Services in the process. New courses include a 10-hour introductory course and 30-hour intermediate course designed to help participants learn Occupational Safety and Health Administration (OSHA) guidelines for responding to workplace hazards in public buildings and facilities. Two additional intermediate level courses cover the latest workplace safety requirements issued by the National Fire Protection Association (NFPA) and Canadian Standards Association (CSA). Also new is an intermediate course covering power system grounding in industrial, commercial and institutional environments. All sessions are presented on-site in a classroom setting, one of the most effective methods of explaining OSHA, NFPA and CSA requirements. Depending on the course, participants receive OSHA certification or continuing education credits upon successful completion.
POWR-GARD Services Electrical Safety sessions are presented on-site in classroom settings, enhancing the learning experience for participants.
Not only has our training program generated profits, but it has opened the door to additional fuse business. Tom Elsasser, POWR-GARD Services Product Manager
The new modules are the latest enhancement to POWR-GARD Services Electrical Safety Training program. Not only has the program generated profits, but it has opened the door to additional fuse business, according to POWR-GARD Services Product Manager Tom Elsasser. Were already ahead of our original forecast. n
| FALL 2009 12