EMC partnered with NMA (Northumberland Manufacturing Association) Clarington Board of Trade and Ajax-Pickering Board of Trade – a large collaboration for the Greeley Containment & Rework Inc SIG in Bowmanville in June.
Company Profile: Greeley are the newest members in our Durham Consortium and hosted almost immediately. A 100% Canadian owned, non-unionized private company since 1999, they provide world class service in detecting and stopping the flow of non-conforming parts by the major OEM’s, General Motors and Tier 1 and 2 suppliers. Providing services in Sub-Assembly, Rework & Repairs, Repacking & Kitting, Sequencing, Warehousing, Transportation and Final Vehicle Inspection. They also do Quality Inspection & Sorting and Customized Programs & Reporting. That is a long list. In short they are doing well, proud of their facility but mostly the capabilities of their employees.
During this SIG we discussed 2 areas of interest
- Benefits of Customized Software Solutions
- How We Save $80-$100 K/Annually on WSIB Premiums.
Benefits of Customized Software Solutions
The issue of purchased software packages is that there are generic in order to be utilized across all businesses, therefore companies rarely use all the aspects they have purchased. It is frustrating to know the data is available but you cannot access the results you want from your system. Personalized software improved productivity and efficiencies. Data can be integrated with your current software packages. All data is held in a database file and can be exported or linked such as with
- Visual Manufacturing
Imagine linking into your ADP database to generate the reports you want and need to drive accountability and improvements!
- Greeley customized software and reporting was developed specifically for General Motors Oshawa, uploading data to GM’s system every 15 minutes, 24 hrs per day. GM’s on-time delivery of vehicles has increased substantially and Greeley has been awarded the exclusive provider for 9 years, just recently awarded another 3 yr contract.
- In an effort to increase productivity by 15%, they implemented scanning measuring scan data per employee per day. Capturing first and last scans vs start and end of shift, start/returns from break and time between scans. This presented to each employee showing their performance held accountability and increased production by 1500 seat tracks per week.
How We Save $80-$100 K/Annually on WSIB Premiums
On the verge of bankruptcy in 2008 Greeley looked for cost savings across the entire organization. Their WSIB Premiums averaged over $100,000. The WSIB Classification Unit, “Rework” was based on the most technical job they were performing using hand tools and consumables. The rate $3.03/$100. However, they estimated 70-80% of their work was Quality Inspection without hand tools and consumables. Research showed this rate to be only $0.38/$100!
After months of discussion with WSIB they obtained approval for two rate groups. (they now have four) They were able to reconcile the entire prior year with the two new rate codes which resulted in a refund of $98,635.81. Their savings to date from this change is estimated at over $850,000.
Criteria for Multiple Rate Groups
- WSIB generally approves multiple rate codes by how a company invoices.
- Different jobs within your facility may fall under different rate groups.
- Must allocate employee hours/direct labour cost against each specific job
- Each specific job is allocated towards a rate group
- Employee hours are reconciled against Payroll
- Final reconciliation, including salaried and auxiliary costs
We thank Greeley for opening their doors with a full plant tour followed by their presentation. Greeley has open capacity for rework and space, if you have an interest please contact me and I will connect you appropriately.
Thank you to Northumberland Manufacturing Association, Clarington Board of Trade and Ajax-Pickering Board of Trade for their collaborative efforts in marketing out this event. It was surely considered a success by those who attended.
For more information on how to both attend or host an upcoming event please contact me to discuss the details. This was the last SIG for the summer in the Durham Consortium but the Fall SIG Calendar will be coming out shortly so keep your challenges open for discussion and let us continue to “steal with pride” from each other to keep manufacturing strong in Canada!
I wish you a safe and happy summer!