VOA Canada Inc. presented two of their projects from their corporate team building event.  The best teams from each Autoliv plant present at this event.  One of the projects from VOA Canada Inc. in Collingwood was based on ergonomics and the other was based on cross training.

The presentation, given by David Helm, Plant Manager, highlighted the two projects and the approach and results.

Project - E-Go Friendly

• Objective - eliminate ergonomic injuries in the inspection department by the end of 2008
• Problem was defined - customers needed larger rolls and the inherent difficulties in handling the larger rolls
• Solution Selection Process and Action Plan
  • Used an idea board with current state pictures and asked for input for changes
  • Examined and tested actions and improvements from the Idea Board
    • Workstations redesigned
    • Added pallet lifter
• Results -
  • reduced ergonomic injuries to zero in 2008, 2009, and so far in 2010
  • 260% improvement in distance carrying rolls
  • 33% improvement in labour cost
  • Roll size improvements
  • Easier access to pallets to move them
• Prevent Recurrence
  • Training - correct lifting techniques
  • Stretching program
  • Job rotation
  • Added foot pedals, automatic tape sealers, electric scissors
  • Moved inspection machines closer together

Project - The X Factor

• Cross Training - current workforce at bare minimum.  To avoid further layoffs and losing valuable skills and knowledge, cross training was needed
• Objective to reduce the LMPU by 20% by the end of 2009 even if the volumes stayed low.
• Selected a cross functional team of Shift Leaders to do the project
• Root cause = Life's not always as hard as you make it!
• The mindset was that it takes 4 months to train someone - but broken down into tasks showed that this is not so for all tasks involved with the positions within the departments
• Broke it down into difficulty levels and started training in the simpler tasks
• Rolled out training
• Result - 22% reduction in LMPU (Labour costs)
• Track hours that folks do in other areas to track and reinforce training

Discussion included how the improvement teams were organized.  VOA couldnot shut down production but could assign times each week that would allow the employees from the shop floor to get together to work on their projects.  There was a team coordinator from admin trained in all the problem solving skill sets who was able to assist the teams.