Who Moved My'Blades

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Who Moved My.Blades?
Proactive Measures In A Rapidly Changing Global
Environment
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Our Company
Speed Is Our Competitive Advantage
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THE GROUP
PCI Columbus Georgia
BTL Nahariya Israel
XAT Xian China
TECHJET Tefen Israel
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PCI Columbus, Georgia (Fac. 1)
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PCI - Columbus, Ga. USA New Campus
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MAJOR CUSTOMERS
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Product Samples
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PCI PRODUCTS
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Fusion Drivers Callaway Golf
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Customer Quality System Approvals

• ISO 9002
• NADCAP
• AS 9100

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Our Culture.The Big Secret !!!
Speed Is Our Competitive Advantage
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PCI Leadership Model
Managing
Leading
LACKS EMPATHY EMPATHY
NO CREATIVE RISK TAKING RISK TAKING
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Lean SigmaIdentify Eliminate Waste

• 6S / VISUAL FACTORY

• TOTAL PRODUCTIVE MAINT.

• SIX SIGMA

• SETUP REDUCTION

• MISTAKE PROOFING

• STANDARD WORK (ONE-PIECE FLOW)

SPEED Is Our Competitive Advantage
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SIX SIGMA METHODOLOGY
Measure
PARETO/GAGE RR PROCESS MAP/XY MATRIX FMEA
DEV/PROCESS CAP MULTI-VARI ANALYSIS 2SAMPLE
T-TEST REGRESSION ANALYSIS HYPOTHESIS TESTING
CRITICAL X DESIGN OF EXPERIMENT FMEA
IMPLEMENTION CONTROL PLAN VALIDATION
LEAN MANUFACTURING
Analyze
4 PHASE APPROACH TO SIX SIGMA
Improve
Control
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Quality Products Are Produced By Quality Minds

• A Refreshed Mind Produces Good Quality
• Has New Ideas
• Is Excited About Change
• Has No Boundaries
• Never Believes in The Impossible
• Takes Ownership in the Product Customer

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Which Place Do You Think Refreshed Minds Might Be
Found?
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Our Philosophy By Design
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Lean Sigma(Mfg)Creating Value By Eliminating
Waste
Speed Is Our Competitive Advantage
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TYPICAL FACTORY (DEPARTMENT SPECIALIZATION)
RAW MATERIALS
DRILL
TO FINISHED STORES
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4
5
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HEAT TREAT
MILL
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2
6
LATHE
LATHE
SAW
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Forge Product Cells
MAIN AISLE
Identify Eliminate The 7 Wastes.I Wont Bore
You With This !!! Too Much Low Fruit In Other
Places
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Lean Sigma In Other Areas
Speed Is Our Competitive Advantage
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E-Company Business Administrative Lean Sigma

• Physicians List
• Benefit Information
• Employee Handbooks
• Electronic Job Posting
• General News
• Leadership References
• Professional Development
• Environmental, Health, Safety
• Electronic Forms
• Retirement Planning
• Savings Program Changes
• Education Assistance
• Tax Forms
• and many more

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Interactive Training Center

• Interactive computer-based learning culture
• Narration, digital movies/slides and keywords
  enhanced the learning process
• Testing of learned material validates learning
  process
• Every PCI Operations jobs have a interactive
  program
• Allows for crosstraining and new-hire training,
  provides recordkeeping of where employees may
  need help on certain parts of their job, and
  reduces learning time and labor required to
  perform the training.

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On-line Purchasing Administrative Lean Sigma
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Paperless ManufacturingAdministrative Lean Sigma
On-Line Mfg / Quality Procedures
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Lean Sigma - EngineeringStandardization
Simplicity Speed
Speed Is Our Competitive Advantage
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Automated Design
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Auto Design Electronic Prints
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Simulation Virtual Processing
Heading - Forming
Heading - Temperature
Forging General Flow
Forging - General Flow
Forging - Material Stress
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Process Simulation
Simulate Operator Loading w/Gravity
Converging Flow Creates Glass Lines
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Generic Fixtures - Standardization
SMALL
MEDIUM
LARGE
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Near-Net Shape Design
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In-House Tooling Make
Control Variability and Quality in Process
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Materials Control Lab

• Specimen Preparation
• Micro and Macro Analysis
• Tensile Tests
• Chemical Analysis

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In-House Cutter Design Make
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Stereolithography

• Prototype Parts
• Soft Tooling
• Hard Tooling
• Quick Tooling

SS/Bronze Nylon/Glass Elastomers
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Layout Product Verification

• Manual Probing to Model Comparison

• Scanning to Model Comparison

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Integrated Automated Gage Layout
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Dual Wheel Robotic Polishing
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Robotic Forge Application
Repeatability Quality
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New Grinding Technology

• High CPK Parts
• Closed-Loop
• Short Lead time
• Quick turnaround
• Small Batches
• Low Tooling cost
• CBN Capability

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Machine Design for Process Control
Speed Is Our Competitive Advantage
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Equipment Monitoring
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Process Monitoring
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Entire Cell Monitoring
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Electronic / In-Process Monitoring

• In-Process at Press

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Bottom Line.Does It All Translate ??
Speed Is Our Competitive Advantage
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1st Only GOLD SUPPLIER
Awarded and Recognized As First and Only GOLD
LEVEL SUPPLIER to United Technologies Pratt
Whitney in November, 2003
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Customer Feedback Analysis
Closest Competitor Scored 4.68
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OSHA RECORDABLES
Translates to EHS Performance
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Revenues By Commodity
2002
2003
2004
(12) New Customers The Build It. Mentality
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Works Well On Other Metrics.
- Long Term Debt was 40 of Sales ZERO TODAY
- Maxd Out Line of Credit CASH RESERVE
- Long Mthly Presentations to Bankers LUNCH TODAY
- Current Ratio of 1.2 3.0 TODAY
- Debt / Equity Ratio gt 1.0 .39 TODAY
- 30 Customer ESCAPES ZERO TODAY
- Less than 50 On-Time Delivery 96 TODAY
- 30 Overtime Rate 9 TODAY
- WIP TURNS of 6-7 30 TODAY
- Angry Conference Calls (DAILY) VISITS FOR
DINNER
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Creating A Passion For Winning
- Make Thrilling Your Customer THE 1 Priority
- Set High OBJECTIVES.Quantum Leap Improvements
- Implement SIX SIGMA LEAN for a Powerful
Combination
- Create the Transformation from the Front.LEAD
IT !!
- Create a SENSE OF URGENCY In The Organization
- LEARN to Understand Identify Waste in the
Organization
- Bring - Learn Teach..Steal Shamelessly !!
- Encourage INNOVATIVE THINKING Among ALL
Employees
- Communicate, Communicate, Communicate
- Work Hard, Have Fun, No Fear.Passion is
Contagious
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The Speed of The Leader Determines The Rate Of
The Pack THATS YOU !!! Dont QUITPERSEVERANCE