Roger’s Core: Practical Problem Solving with the Whole Team

“As Team Leader for 2nd-shift RS Stamping, it is my job to keep our associates safe, ensure the team is stamping high-quality parts for our customers, and doing so as efficiently as possible to minimize costs. We stamp the parts that are assembled into finished evaporators, that go into heating and cooling systems (HVACs) for new cars and trucks. Something as simple as stamping a part wrong could lead to a major issue for a new car owner, so it’s important we’re sharp, focused and accountable.

Our 2nd shift RS Stamping team recently completed a Practical Problem-Solving Project on the reduction of muda (the Japanese word meaning waste) from associate wait time. In the spirit of creativity and problem-solving, we created a simple calculator to determine how much non-operational time we can take to achieve our production ratio goal. We record information based on the number of parts produced, however, our associates think in units of time. By converting quantity of parts into time, we have been able to give associates a better understanding of where they’re at against the target. When associates start thinking in terms of minutes lost, it creates multiple opportunities for improvement and improves our overall quality.

Based on this project, we added a satellite quality station closer to the stamping press because an associate figured out they were wasting 8 minutes per day walking to the old station. We also increased our monthly production ratio by almost 6 percent and have sustained this level for over a year.

Perhaps most importantly, this has increased collaboration and fostered a culture of kaizen on our team, with our associates continuing to actively find ways to save time daily and reduce muda of motion. This project was a success because of the associates and their commitment to improving our process, efficiency and overall quality.”

Roger Cruise

Team Leader, 2nd Shift, RS Stamping

DENSO Manufacturing Michigan (Battle Creek, Mich.)

Members of the 2nd shift RS Stamping team in Battle Creek, Mich. (left to right): Bob Loyd, Robert Rogers, Hiong Boi, Roger Cruise, Van Lian, Brian Beene, Eldon Ulsh, Barry Watson

DENSO is committed to a culture where every associate’s diverse talents and strong passion enable us to contribute to a better world. What’s at your core? What are you passionate about? What drives and motivates you? We want to hear from you.