Today, our global headquarters announced we have developed products for Advanced Drive, an advanced driver assistance technology featured on the new Lexus LS and the new Toyota Mirai. Both vehicles, and our new technology, will be on the road this month!
Advanced driver assistance technologies are essential to helping drivers safely operate vehicles. The products that we have developed will support drivers on expressways and other motor-vehicle-only roadways, allowing the Advanced Drive system to detect hazardous situations, make decisions and assist driving under the driver’s supervision.
With these new products, we will contribute to advanced driver assistance technology that gives peace of mind to occupants and improves the safety of vehicles. They are part of our broader commitment to developing mobility technologies that help create safe and flexible mobility for drivers and pedestrians alike.
To learn more about the advanced driver assistance technologies we’re contributing, follow this link: https://bit.ly/3s4vmGS
Today, our global headquarters announced that we have begun testing a CO2 circulation plant at our Anjo Plant’s Electrification Innovation Center. The new plant will capture CO2 generated by the plant and recycle it as an energy source for the facility, a capability that supports our efforts to eliminate CO2 emissions from our facilities.
More broadly, this CO2 circulation technology can also be applied to not only our production facilities, but to manufacturing sites around the world, which will help with efforts to achieve carbon neutrality.
The plant represents the latest initiative in our broader commitment to sustainability, and our Reborn 21 focus areas of “Green” and “Peace of Mind.” With this, we continue to accelerate our efforts to achieve net-zero CO2 emissions, or carbon neutrality, by 2035.
For more details on the new plant, and our commitment to sustainability, follow this link: https://www.denso.com/global/en/news/newsroom/2021/20210407-g01/
A little over three years ago the HR legal team at DENSO Manufacturing Mexico wanted to establish a production line tailored to associates with a disability. So, with the help of DENSO HSE and a Mexican government organization that focuses on the needs of people with disabilities, the site began looking at studies and conducting trials to identify the specific disability that could safely and effectively be implemented in a production environment.
The group determined that a molding line for those with hearing impairments would work. Today, 14 associates with hearing disabilities work on the line, alongside associates with no hearing impairments. But it didn’t happen overnight. The HR legal team, along with plant leadership wanted to ensure that everyone was prepared and informed, so there was awareness training on non-discrimination and harassment for team leaders and associates. And to assist with communication outside of writing, team leaders and associates that would be working directly with the hearing-impaired associates learned basic sign language.
But it wasn’t just the people that adapted – some plant processes and systems had to be changed. For example, all plant safety and security measures are now visual – alarms/alerts are not auditory – and training on what each light means and what they need to do when they are activated was provided.
Admittedly there were some bumps along the way – getting everyone on board for new processes and mindsets took some time, and awareness training had to be expanded to people working in areas within the facility, such as the cantina, to ensure everyone was comfortable interacting with the hearing-impaired associates.
The line has successfully operated for more than a year and there are plans to not only expand the line to 20 associates, but establish lines, possibly for those with other disabilities, in other plants on the campus.
Congrats to the local DENSO HR legal team in Mexico for making this happen. It’s a great example of how everyone can work together to create a successful, thriving D&I culture at DENSO.
All photos were taken before the COVID-19 pandemic. During COVID-19, DENSO established and continues to maintain safety precautions at all of its locations, including the wearing of face coverings, social distancing and screenings.
In September, we called for associates to nominate exemplary female colleagues for the 2021 STEP Ahead Awards, a national honor given every year by the Manufacturing Institute to the best women leaders in manufacturing.
We asked and you delivered. From the c-suite to the production floor, here are the outstanding nominees you submitted to be considered for the awards:
Please join us in applauding all these DENSO leaders, who make invaluable contributions to DENSO every day and help us deliver on our principles of safety, quality and collaboration. We recognize the important impacts they make not only at DENSO, but in their communities and with friends and families as well.
What’s Next?
While we wished to submit all the nominees, the Manufacturing Institute is highly selective in its review process and only allows 10 submissions per company.
As a result, a DENSO review committee consisting of members from the Diversity & Inclusion Council, Corporate Communications, Human Resources and Government Affairs evaluated and submitted the nominations that best aligned to the awards’ criteria. Those criteria included examples of personal achievement, mentorship, leadership, and community and company contributions through specific results and data.
The Manufacturing Institute is expected to announce the winners on Jan. 8, 2021. If a DENSO associate wins, we will be sure to share!
Want to get involved next time?
Whether you were nominated this year or this is the first you are hearing of the award, know that next year you will have another chance to nominate yourself or another standout female leader from DENSO. We will share more details about how to nominate individuals – and how to make those nominations as strong as possible – closer to next year’s nomination window.
More About the STEP Ahead Awards
Produced by The Manufacturing Institute, an organization dedicated to growing and enhancing the industry’s skilled workforce, the STEP Ahead Awards recognize women in science, technology, engineering and production careers who exemplify leadership within their companies. The honor identifies top talent in manufacturing, and further encourages award winners to mentor and support the next generation of women to pursue manufacturing careers.
National Manufacturing Day is observed every October to emphasize the importance of manufacturing in our national economy. Here at DENSO, we extended the celebration throughout the whole month of October, and asked others to join us!
Students from Tennessee, Michigan, and North Carolina were invited to virtual panels hosted by DENSO associates from DMMI, DMTN, and DMNC. Panel discussions covered a variety of topics within the industry, including the ones listed below and the DMMI associates supporting them:
Thank you to all our volunteers who helped make Manufacturing Month a great success!
If you’re interested, check out the DENSO North America YouTube channel to watch recordings of each panel discussion: www.youtube.com/c/DENSOinNorthAmerica/videos
As part of our continued celebration of Manufacturing Month, we hosted a panel discussion last week that focused on two associates who left not only DENSO but the manufacturing industry altogether for other job opportunities – only to come back!
Ed Fellows and Rich Stanley – both in Battle Creek, Mich., shared their stories about how they got started at DENSO – Rich on the assembly line and Ed as an engineer – how they advanced, why they left and, more importantly, why they came back.
We also took a few minutes to bust some serious myths about manufacturing. Make sure everyone knows our is exciting, clean and full of advancement opportunities for creative and critical thinkers alike! You can watch the full discussion here: https://www.youtube.com/watch?v=nPaUh2PPyhY&feature=youtu.be
This month, we’re celebrating Manufacturing Day every day with virtual panels that spotlight our exciting work, amazing employees and DENSO Spirit to encourage others to pursue careers in manufacturing.
On October 8, we hosted a webinar on Skilled Trades that discussed the critical role these jobs play in manufacturing. One of the panelists, Tommy Cole, graduated from high school just three years ago and is now part of DENSO’s three-year apprenticeship program.
After getting a degree in industrial maintenance from the Tennessee College of Applied Technology in Knoxville, Tommy was offered an apprenticeship with DENSO. Before joining our team, Tommy thought working in manufacturing would mean doing the same thing every day. Now he knows that’s far from the truth and has found a real sense of accomplishment in his work.
Check out what else Tommy had to say about starting a career in manufacturing here! And thank you, Tommy, for showing your DENSO Spirit through continued collaboration, communication, teamwork, and meeting challenges as they come!
If you know someone looking to quickly grow their production or skilled trades careers, we’re hiring! Send them to DENSOcareers.com and apply for open opportunities.
As part of our continued celebration of Manufacturing Month, we hosted a panel discussion this week on the value of safety, health and environment (SHE) practices in the workplace.
Shawn Bryant (Maryville, Tenn.), Ryan Hodges (Maryville, Tenn.), Jody Smith (Battle Creek, Mich.) and Steve Graham (Battle Creek, Mich.) chatted about DENSO’s SHE practices, explaining how our facilities across the country have adapted in the wake of the COVID-19 pandemic. The DENSO Spirit tenant of collaboration has been critical during this time, as we’ve all come together to create safer, stronger work environments. Though some processes have changed, one thing remains the same – DENSO is committed to protecting people’s lives, the communities we operate in, and the facilities that our employees work in.
You can watch their conversation here: https://www.youtube.com/watch?v=A4ZTth7qdwg
We also hosted panels on Robotics, Women in Manufacturing and Skilled Trades. To view these webinars, click the links below:
To celebrate Manufacturing Day throughout October, we’re hosting a series of virtual panels to get individuals excited about pursuing careers in manufacturing! Expert panelists from across our North American facilities will discuss important topics in the industry, like robotics and advanced technology, expanding opportunities for women, career pathways, skilled trades and more.
“Manufacturing does so much for so many, giving people opportunities to positively impact global organizations and society, work with leading technologies, innovate new mobility solutions and grow their careers,” said Melissa Smith, community affairs lead at DENSO. “Manufacturing Day reminds us to celebrate the importance of this industry and those who make it possible, as well as encourage and educate the next generation who will make it stronger in the future.”
If you know someone who’s interested in pursuing a career in manufacturing and portrays DENSO Spirit traits like credibility, foresight and collaboration, learn more about our panel discussions and invite them to register today: https://bit.ly/33CxBYS
As the first female machine technician at DENSO’s Guelph, Canada, facility, Pauline Fell is a trailblazer at the company. But this “DENSO first” isn’t her only achievement. During her 20-year career she has accomplished much more and is regarded as a role model for women in manufacturing.
Using her DENSO Spirit and expertise, Pauline, now a machine tech sub leader, identifies an area for improvement and takes the initiative to fix it. For example, after seeing the nearly 100 pages of preventative maintenance checksheets printed by the machine tech department every month, Pauline adopted the computerized maintenance management system used by the maintenance department. With the electronic system, previous time-consuming tasks are now done more efficiently and effectively, maintenance checks are easily updated and alerts are sent if a check is missed. Additionally, she is working on creating work instructions on how to complete each task.
“It’s a work in progress, we’re continuing to identify additional machines within the plant where work instructions can be implemented,” she said.
Her talent and problem-solving skills have also come into play during internal Quality Circle competitions and at the 2015 Honda Fall CAN Conference, where her team finished in first place. How does she do it? With a calm and analytical approach to problem solving: “Getting riled up doesn’t serve any purpose, so there’s no point in stressing yourself out.”
Utilizing all this experience, Pauline takes a special interest in mentoring other female machine techs, helping them develop mechanical skills, improve their understanding of maintenance systems and apply for full-time positions. Her career success and dedication to mentoring current and future female manufacturing professionals were reasons for her nomination to the Manufacturing Institute’s 2020 STEP (Science, Technology, Engineering and Production) Ahead Awards, which recognize women in these career areas who exemplify leadership within their companies.
From the production floor to the C-Suite, female DENSO leaders help us deliver on our principles of safety, quality and collaboration. And, in recognition of their invaluable contributions, we’re calling on associates to nominate exemplary women colleagues for the 2021 STEP Ahead Awards. Details on the awards and how to nominate someone are below. All submissions are due by Sept. 17, 2020.
A review committee consisting of DENSO’s Diversity & Inclusion Council, Corporate Communications, Human Resources and Government Affairs will evaluate the nominations for examples of personal achievement, mentorship and leadership.
The committee will select the best nominations to submit to The Manufacturing Institute for consideration, favoring those that include impactful stories, specific results and data.
If the committee selects your nomination, members of the committee will work with you to edit and submit the final nomination to the Manufacturing Institute by their award deadline, Oct. 2.
More information: www.themanufacturinginstitute.org/women/step/step-awards/
At DENSO, we have a long history of producing products that push electrification technologies into the future. Last week, we doubled down on our promise to produce electrified automotive products, systems and technologies by opening an Electrification Innovation Center in Ajno, Aichi, Japan.
DENSO has long been a pioneer in hybrid and electric vehicle technology, and that tradition continues today. In 2018, it was a large part of our Second Founding, which focuses on key initiatives like electrification, automated driving, connected cars and other non-automotive business areas to prepare us for the future. This facility will help advance that commitment and rapidly transform new ideas into high-quality electrification products for our customers. Better yet, our associates will also create new energy conservation tech to help us reach our zero CO2 emissions goal at the new plant!
The Electrification Innovation Center will include:
To learn more about how this Electrification Innovation Center will support our commitment to a more sustainable future, click here.
In recognition of our commitment to creating the future of mobility, DENSO was named to PatentSight’s list of the Global Top 100 Digital Innovation Leaders. Out of the 100 global leaders listed, DENSO was ranked 22nd overall and eighth among global autonomous driving companies.
This recognition comes after several key initiatives we’ve implemented in the past year to support our Second Founding and Long-Term Policy 2030 – like opening R&D locations in Montréal, Plano, Texas and Seattle and creating our first Smart Mobility Ecosystem in Dublin, Ohio. These initiatives, and ultimately this recognition, would not be without the hard work and dedication from our associates.
“At DENSO, we strive to create technologies that promote safer roadways and communities, are cleaner for the environment and streamline transportation,” said DENSO’s Kenichiro Ito. “We are proud to be recognized as one of the world’s most innovative companies as we continue to change the way the world moves.”
To learn more about DENSO’s placement in PatentSight’s list of the Global Top 100 Digital Innovation Leaders, click here.
The COVID-19 pandemic is causing a shortage of medical supplies across the world, so when DENSO Manufacturing Tennessee (DMTN) reached out to Blount Memorial Hospital to see how we could help, the DENSO spirit took over.
“They are in dire need of face shields,” said Britt Autry, DMTN Vice President. “Our associates stepped up, designed a product, developed modeling and had a prototype within a day.”
Since Tuesday, March 24, a visor and shield have been designed and produced. After several modifications, a molding die started being developed for both parts and DENSO purchased straps to assemble the face shield.
Three days later, 30 DENSO face shield prototypes were donated to Blount Memorial Hospital. This week, an additional 75 prototypes are being sent to Fort Sanders Regional Medical Center and East Tennessee Children’s Hospital.
“We can’t thank DENSO enough,” said Alissa McMahon, BMH Director of Quality Management. “Everywhere you look, medical supplies are hard to come by. You are making us – and I’m sure eventually many other hospitals – extremely happy.”
Over the next two weeks, DMTN associates will install production cells in Building 204 to begin mass production. The line should be complete by April 8.
“This is DENSO spirit at is finest and fastest,” said Mark Moses, Intelligent Cockpit Director. “From idea, to design, to production, through safety and legal, it’s been a team effort and everyone should be extremely proud of what we can do together.”
DMTN’s Britt Autry demonstrates how the DENSO face shield is assembled to Blount Memorial Hospital’s Alissa McMahon.
Blount Memorial nurses show off the recently designed and 3D printed face shield prototypes DMTN will start producing in the next couple weeks. Pictured (L to R) are: Cara White, Holly King, Mariah Moore, Ari Small and Barbara Cave.
The DENSO face shield, to be produced in Building 204, says “Thank you for taking care of us!”
DENSO is letting our example shine by turning up the lights and turning down our energy usage! In December, DENSO Manufacturing Michigan, Inc. (DMMI) received a $377,737 rebate from Consumers Energy through their Business Energy Efficiency Program.
DMMI is one of the top 10 highest energy users for Consumers Energy in the State of Michigan due to the requirements of our compressed air systems and industrial brazing furnaces. This means we must continuously look for ways to save energy to reduce our environmental impact and save money. In recent years, multiple lighting and energy saving projects have been implemented in the parking lot and boiler areas. This latest rebate was for full plant lighting replacement and advanced controls such as those used for controlling light activation on motion sensors in the scrap dock area.
Induction lights throughout the plant were replaced with LED lights featuring wireless control capabilities. The plant is now much, much brighter, with LED lights that can produce more than three times brighter light while using less energy. In addition, the Facilities department maintains a computerized system that controls the lights within an overall Facilities Management System.
The cost and environmental impact is tremendous—280 tons of CO2 emissions per year are saved from the project, and the amount of energy saved is equivalent to the annual electricity usage of 144 homes.
The monetary return from the project exceeded our expectations by over $90,000. The rebate will allow the Facilities department to help offset utility expenses from 2019 fiscal year.
Associates can play a key role in making improvements by looking for energy waste in their own areas. If you see an area for improvement or have an idea, please speak up!
Since joining DENSO, Andrea Caratti, from Northern Italy, has been able to cross off many major cities in the United States from his travel bucket list; Chicago, Washington DC, and New York City to name a few. After recently accepting a new role, Caratti is venturing further into the U.S. as Plant Manager of DENSO Manufacturing Michigan Iowa (DMIA).
Caratti started his career with DENSO six years ago at DENSO Thermal Systems S.p.A. (DNTS) in Italy. DNTS is a part of DENSO TEC, the Thermal Europe Center. As the Logistics Manager, he enjoyed getting to work with many of DENSO’s customers within the Off Road Special Applications Business Unit (ORSA). This group makes parts for bigger, off-highway customers, like John Deere. In his new role at DMIA, he will continue working with these customers.
Caratti came to DENSO with a master’s degree in automotive engineering and work experience at Fiat-Chrysler Automobiles (FCA) headquarters in Auburn Hills, Michigan.
Caratti said he is looking forward to the new challenge.
“I’m very thankful for it, and know that we will all do a great job together,” Caratti said.
One element Caratti said he’s not looking forward to is winter. His favorite hobby, outdoor cycling, will have to wait until spring returns to Iowa.
Caratti has enjoyed seeing new perspectives of the company, and said he looks forward to continuing to interact with other DENSO plants.
Congratulations on your new role at DENSO!
We make things. Even if we don’t work on the manufacturing line, or design or sell our technologies, we all have a role in making things.
We’re celebrating manufacturing all month long! See how we’re busting manufacturing myths, and celebrating National Manufacturing Day across the region.
To inspire the next generation of manufacturers, DENSO is celebrating Manufacturing Day today and throughout the month with a variety of programs and events at our locations across North America.
Our 70-year history is rooted in crafting advanced automotive components and systems for almost every vehicle make and model on the road. Today, DENSO is at the forefront of automated and data-rich manufacturing, or Industry 4.0, and provides tech-forward training for our associates to learn new skills and advance their careers.
To addresses common misperceptions and the stigma around manufacturing, DENSO is excited to host student tours at our Maryville facility; review manufacturing-themed essays from students in Athens, Tennessee, and Osceola, Arkansas; and visit colleges and universities in Michigan, Mexico and North Carolina to showcase the rewarding careers possible in the field of manufacturing. For more details on these community events and programs, read our press release here.
“Too often, there is a stigma around manufacturing, but the fact is this – manufacturing is changing the world,” said Shinichi Nakamizo, executive officer of DENSO Corporation and North American Manufacturing, and president of DENSO’s Maryville, Tennessee, facility. “Manufacturing allows us to keep pace with the new demands of mobility. It creates an environment in which our employees can learn new skills and excel. And it allows us to build a collaborative, diverse and inclusive workforce that is helping revolutionize transportation and move society forward.”
On Sept. 8, DENSO once again held DENSO Group Safety Day to reinforce its commitment to safety and remember the 1969 explosion at the Anjo plant, which resulted in the deaths of six people.
Since that tragic event, DENSO has implemented policies, departments, standards, systems, initiatives and more – all focused on safety. Today, safety is engrained in the way we work together as One DENSO, the DENSO Spirit and a foundational component to reaching the goals outlined in our Long-term Policy.
A shining example of this safety mindset was celebrated at DENSO Manufacturing Arkansas on Sept. 5. During the celebration, associates were honored for reaching a tremendous milestone – 7 million hours without a lost-time work incident.
And how did they achieve such an amazing accomplishment? Having a “Safety First” mindset from the first time an associate walks in the door, according to Stephanie Patterson, RN at DENSO Manufacturing Arkansas.
From the moment an associate begins the onboarding process for their career at DENSO in Arkansas, a variety of safety topics are addressed. But it’s not only the importance of safety that is discussed, it’s the importance of a collaborative effort to make safety a priority. Everyone at every level is responsible, whether they are part of the Safety, Health and Environment (SHE) team or not.
“Safety is always evolving – it changes every day. We have to rely on our associates’ information and experiences to ensure we are addressing all safety issues or potential concerns,” explained Patterson.
When an associate identifies something wrong or safety related, they immediately report it to the SHE team, who instantly addresses the concern. Every incident, regardless of the size, is documented, investigated and results are communicated to associates. This not only creates a respected and valued relationship between all levels and disciplines, but reinforces that safety is not just something they talk about, it’s something they live.
“Our daily job is to keep the plant a safe and healthy working environment for everyone here,” Patterson added.
Safety is a critical part of our future. Productivity, efficiency, technology development, talent attraction/retention, competitiveness – all rely on safety in some way. For example, we can’t be efficient if work stops due to ongoing safety issues. And, we won’t retain talent if they don’t have a safe environment to work in.
So, let’s congratulate our DENSO Arkansas team on 7 million hours (and cheer them on to 10 million!), and ensure that we all do everything we can to create a safe environment for ourselves and those around us.
We are incredibly proud of our facility in Osceola, Arkansas, that has achieved 7 million production hours without a lost time accident! The work our associates have put toward elevating safety standards and adapting policies to ensure the best working conditions is a testament to the commitment DENSO has made to create a culture of safety at our facilities around North America.
On September 5, 2019, DENSO Manufacturing Arkansas will host a celebration of this milestone as part of “Safety Day.” Learn more about this achievement here.
“As manufacturing evolves, so too must our practices to keep employees safe,” said Kenichiro Ito, senior executive officer for DENSO Corporation and chief executive officer of DENSO’s North American Headquarters. “Our employees drive DENSO’s success on a national and international scale. Their health, safety and happiness are of paramount importance, so it is crucial that we promote safety policies that offer the best protections possible.”
The next CoA (common, compact, collaborative) HVAC line started production at DENSO’s manufacturing facility in Battle Creek on July 22. Although it is the second CoA line, associates throughout the region made sure it is a project filled with firsts.
“The goal for this project was localization, and it was a huge development opportunity,” said Mike Curbey, HVAC Engineering Manager. “This is the first CoA line in the world to be built 100% locally.”
CoA2 is also the first HVAC line with IoT (Internet of Things) connectivity and the first line at DENSO in Battle Creek with a collaborative robot.
Senior Engineering Technician Eric Paulson said that the team at DENSO in Battle Creek worked closely with machine builders at DENSO in Maryville, Tennessee on the localization effort.
“One of our biggest challenges was helping the machine builders understand our needs exactly,” Eric said. “We were starting with something originally designed in Japan and asking the DENSO Tennessee team to build it to the specifications of our local needs in Michigan. We just had to figure all of that out.”
The new line will produce HVACs for three Subaru models produced in the United States. Subaru of Indiana Automotive (SIA) has already recognized the line as a world-class process.
Congratulations to everyone that made the HVAC Auto Line 2 a reality over the last two years. This is a big step towards DENSO’s future!
Earlier this year, Dr. Jeff McCord was named Commissioner of the State of Tennessee Labor & Workforce Development Department. Hand-picked by Tennessee Governor Bill Lee, Dr. McCord oversees divisions and programs that provide a vast array of services that support jobs and workforce development.
Last week, Commissioner McCord visited DMTN Plants 203 and 204 to talk about workforce development, tour the facilities and talk with associates. The first member of Governor Lee’s staff to visit DMTN, Commissioner McCord said he was very impressed with the DENSO facilities and associates. During remarks to plant and Maryville Community leadership, he pledged to continue workforce development programs during his term.
Ongoing workforce development is critical to help DENSO meet its Long-term Policy 2030 – without talented associates, we cannot achieve our goals – and it supports the United Nations’ Sustainable Development Goal (SDG) number 8: Decent Work and Economic Growth. The SDGs are a global, shared blueprint for peace and prosperity for people and the planet, now and into the future.
Thank you to those who made this high-profile visit possible: Mr. Nakamizo, Chuntao Ye, Jack Helmboldt, Britt Autry, Charlie Chujo, Mike Peevy, David Byrum, Kay Morrison, and the DMTN S&H/Communications/Community Relations/GA/HR/NAITS teams.
Click here to read McCord’s comments on his visit and view more photos.
Commissioner McCord talking to DMTN associates on a tour of the plants.
Through 24 years of service at DENSO in Battle Creek, Machine Technician Art Fields has never called in sick. Yes! 24 years of being at work on time, every day that he is scheduled.
“My dad helped instill my work ethic. If you want something, you need to work hard for it and take pride in the work you do,” Art said.
After starting as a temporary, Art was hired in as an associate in the same area that he works in today, building radiators for automotive engine cooling modules. As a production associate, he enjoyed opportunities to work on machines and problem solve with the Machine Technician in his area. This inspired him to become one, a job he’s held since 1998.
Working at DENSO means Art has worked with people from a lot of different cultures, one of his favorite things about the company. Regardless of background, though, Art said his coworkers are always polite and willing to help.
Art enjoys participating in company-sponsored events such as golf outings, bass tournaments, company picnics and sports outings. Outside of work, Art keeps himself busy with his hobbies and activities with his family. He fishes with the Battle Creek Bass Busters every Saturday during the season and plays disc golf multiple times a week to stay active.
Art said he has witnessed a lot of growth and change at DENSO during more than two decades in Battle Creek.
“When I first started I saw how clean the place was and how they cared about their people. I knew it was a long-term company that wouldn’t be going anywhere, so I wanted to be hired in.”
“It’s been a good feeling watching DENSO grow – I’ve seen it expand and add on at least 5 times. My goal is to retire here.”
Congratulations Art, and thank you for your dedication!
Know an associate with an interesting story to tell or milestone to celebrate? Email DMMI_Communications@denso-diam.com.
Bradley Farman loves to learn. In addition to living in three countries and learning three languages, he decided to apply for a summer internship at DENSO.
A mechanical engineering student at Montana State University, Bradley wanted to find an internship in the automotive industry. A family connection led him to apply for an engineering internship at DENSO’s thermal facility in Battle Creek, Michigan. After interviewing for the position, the offer to work in the Condenser Engineering department brought him from Montana to Michigan to help kaizen condenser processes.
“The most valuable thing I’ve learned here is how to take a project with a big scope and break it down into bite sized, more manageable parts,” Bradley said.
Bradley is the intern who traveled the farthest to spend the summer at DENSO, but travel is nothing new to Bradley, who has lived in more than eight cities and three countries in his life. He also enjoys learning new languages. He is currently learning French, having English, Spanish, and Japanese under his belt already.
Thanks for sharing your talents with us this summer, Bradley!
Who knew a bin of scrap materials could save DENSO $223,000? Ron Carr made this happen on a global innerfin condenser (GIC) production line at DENSO Manufacturing Michigan (DMMI) in Battle Creek.
Ron’s idea took just one hour to build, but it’s had tremendous impact. He used leftover SUS materials to build a lazy-susan turntable that allows associates to rotate cores easier and faster. A sensor in the middle of the turntable also helps parts move when associates are ready for the next step. This has helped reduce cycle time, in addition to improving safety and reducing the risk of repetitive strain injuries for associates.
Ultimately, Ron’s idea reduced both the number of people needed to build the part and the time it takes to build it. These savings really add up! In addition to saving DENSO $223,000 per year, Ron also submitted the idea to the DMMI associate suggestion program called BEAM—Because Every Associate Matters. Through BEAM associates receive a portion of the cost savings for one year. Ron’s turntable idea earned him over $8,000.
“My family loves to take trips together, so this money will help us do that,” Ron said.
Ron was also able to crossline his idea to new GIC lines. During his four years as a DENSO associate, he submitted multiple BEAMs before moving to his current Team Leader position, and says that submitting a BEAM is a fun way to stay engaged at work.
“I encourage my Subleader and Machine Tech to do a BEAM every year. It’s an awesome program and there are a lot of people with great ideas out here that could be implemented.”
Associates with a great improvement idea to share can contact Associate Relations or the Manufacturing Improvement Team to learn more about the BEAM submission process.
It was only a small piece of plastic that brushed Jacob Klepper’s work boot, but he knew it was a big deal.
Jacob has been building and packing engine cooling modules at DENSO Manufacturing Michigan for over a year now, so he recognized the piece could have been broken off of a finished part headed for a customer. He immediately stopped the line and called his Team Leader, Stan Thuazathang.
Stan arranged for Jacob to conduct a sort of finished parts in the warehouse, determined to find the source of the broken unit. An hour and a half later, Jacob discovered the broken radiator and removed it to be repaired.
“I knew the prong was a customer use point, so we could have received a quality defect claim,” Jacob said. “That would have cost DENSO a lot of time and money if it had gotten to the customer’s assembly line, so I’m glad I was able to find it.”
Stan said this is not the first defect that Jacob has found, and appreciates his hard work and dedication to protecting DENSO’s customers.
“Jacob is a really great worker,” Stan said. “His attention to detail is excellent, and I know we can count on him to speak up when he sees something wrong. That’s really important for all of our associates, so Jacob is setting a great example.”
DENSO in Battle Creek is lucky to have 10 college interns working throughout the facility this summer. One of them is Hannah Pearl, a University of Michigan (U of M) student. She is spending the summer in the Total Industrial Engineering (TIE) department, focusing on implementing autonomous mobile robots into the radiator and ECM final assembly areas.
Hannah has several years of DENSO experience. Last summer, she interned with Production Control TIE and helped launch a yard management system. Before college, Hannah was involved with DENSO through a high school internship program in heater core and evaporator engineering while she attended the Battle Creek Math & Science Center.
“The people at DENSO are my favorite part,” Hannah said. “It’s awesome when you walk down the hall and everyone is friendly and will talk to you.”
At school Hannah is a campus tour leader and volunteers her time with Young Life, a youth group for middle schoolers. She enjoys traveling, and has a goal to be out of the country at least once a year. So far, a service trip to Mexico has been her favorite because she loved bringing hope into people’s lives.
This fall, Hannah will begin her junior year at U of M, continuing her studies in Industrial and Operations Engineering.
Thanks for being a part of the DENSO team, Hannah!
Basketball and quality targets may seem like an unlikely combination, but the DENSO Production Control (PC) team in Battle Creek combined the two into a competitive March Madness Critical Lockout Challenge with championship results.
PC teams were divided into ECM and HVAC plant brackets and advanced based on the smallest number of critical lockouts. Lockouts can occur when parts in the warehouse are scanned to the wrong order, or if parts are not scanned into inventory.
“Lockouts are the tip of an iceberg, so if we manage them properly we’ll see improvements throughout the whole process that better protect our customers,” said Derrick Boyd, PC Section Leader. “Every day, at least 40 people are scanning parts for more than a dozen customers going on about 120 trucks, so we need ways to help everyone stay focused on what they’re doing.”
The challenge was fun for associates, and also helped DMMI achieve their lowest month of critical lockouts for the year. The top two teams ended the competition strong, having zero lockouts during the entire 4 week challenge! HVAC Plant finalists were team “Uncle Charlie” including Richard Martin, Jaymes Marriott, and Audra Blowers. The ECM Plant winner was “Team Adam” including Damion Adams, Timothy Barnes, and James Ayer.
“Lockouts put our customer at risk,” said Damion Adams, Advanced Associate. “This challenge got competitive because everyone was striving to do their personal best, so it helps us better focus on our job and do our part to keep customers happy.”
Team Adam was ultimately declared the champion because they had more opportunities for lockouts to occur. Each team member was awarded a Lockout Champion T-shirt and a $50 gift card. Runners-up were also awarded gift cards.
“The goal is to keep lowering our EPM (Errors per Million) by continuing to motivate our associates through challenges like this, bringing their attention to what causes lockouts, making process improvements and making sure our production team stocks in parts accurately to avoid delays and ensure high levels of inventory accuracy,” said Adam Senchuk, PC Manager.
Jeremy Shirey – Estimated completion: July 2019
Jeremy enjoyed being part of a team and resolving a variety of challenging tasks in his Machine Finishing rotation. He is thankful for all the talented individuals who have helped him throughout the program, and believes DENSO is fortunate to have so many skilled journeymen!
When he’s not at DENSO Jeremy loves spending as much time as he can with his wife and their new puppy.
Andrew Fry – Completed April 2019
Andy is thankful for everyone who helped him grow his skill set, as well as his wife who supported him and accommodated to his changing schedule during the program. His favorite part of the Apprenticeship Program was Machine Finishing.
When he’s not working, Andy spends as much time as he can on the lake with his family.
Shane O’Neil – Completed March 2019
Throughout the program he enjoyed rotating through the different groups which allowed him to meet and work with all the journeymen, and learn multiple repair techniques. Shane is thankful for Paul Phillips who helped him launch a new mod machine C-1211 during the program.
Outside of DENSO Shane enjoys fishing and riding dirt bikes with his two children, and looks forward to taking his family on camping trips.
Richard Saylor – Completed February 2019
Richard appreciates the numerous people in each department that helped him learn important skills so he can succeed in his job. His favorite part was being rotated through the different areas allowing him to gain a variety of experience.
Something not everyone knows about Richard is that he started working on cars when he was only 13 years old!
DENSO Manufacturing Michigan, Inc. associates have donated 2,726 pounds of food and 118 hours to the Food Bank of South Central Michigan over the past twelve months. Recently, 18 associates spent the afternoon assembling weekend school packs for kids as a part of DENSO’s work-time volunteer program.
In this program, each associate can volunteer eight hours of paid time each year through company-sponsored events. From sorting donations and stuffing envelopes to assembling food bags, DENSO associates are empowered to give back to the community.
Thank you to our work-time volunteers!
It was our honor and privilege to host Shinsuke J. Sugiyama, Ambassador of Japan to the United States, at DENSO Manufacturing Tennessee (DMTN) in February. During his visit, Ambassador Sugiyama toured parts of the facility and met with DENSO teams to learn more about the company and our global collaboration efforts.
Ambassador Sugiyama was impressed with the speed of development at DENSO and the global collaboration between Japan and the U.S.
“What I see today is the best example of collaboration between Japan and the United States that I have ever seen,” said. Ambassador Sugiyama. “Japan and the United States are doing some really fantastic things at DENSO.”
During the presentations and discussions throughout the day, Ambassador Sugiyama’s was focused on two key topics: hiring talent and associate life, such as housing and medical treatment options.
DENSO teams shared how we are being more creative in our recruiting efforts, and how we’re tackling the competition for talent from many different angles, including working more closely with colleges, technical schools and high schools to develop and recruit talent.
Ambassador Sugiyama also displayed a genuine interest in DENSO associates’ working and living conditions. DMTN highlighted its onsite medical treatment facility for associates and family members, fitness center, and other on-site amenities.
“This was the first time any Japanese Ambassador to the United States visited our DENSO facility in Tennessee; we were proud to host him and showcase our associates and efforts,” said Jack Helmboldt, president of DMTN. “DENSO’s leadership was extremely impressed with Ambassador Sugiyama’s knowledge of the challenges manufacturing companies face and his strong interest in how DENSO is addressing those challenges. It was truly an honor to meet and share our facility with him and his team.”
Hosting Ambassador Sugiyama is one of many efforts DENSO is taking to strengthen its diplomatic relationships. As a global company, DENSO is dedicated to establishing stable economic relations based on mutual trust. To do so, we believe it’s important to learn, discuss, collaborate and understand the common interests of other countries.
Pictured front row (L to R): Masahiko Uchino, Second Secretary, Embassy of Japan in the USA; Jack Helmboldt, DMTN President; Shinsuke J. Sugiyama, Ambassador of Japan to the USA; Hiroyuki Kobayashi, Consul-General of Japan in Nashville; Kenichiro Ito, CEO, DENSO North America and Itsuro Abe, Consul, Consulate-General of Japan in Nashville. Back row (L to R): Masato Kitamae, DMTN Executive Project Leader; Toyohisa Nakano, DMTN Executive Coordinator; Chuntao Ye, DMTN Senior Vice President; Hidecki Ichikawa, DMTN Executive Coordinator; Marty Deschenes, DMTN Vice President; Bob Booker, DMTN Senior Manager and Jennifer Heckmann, Senior Program Manager, DENSO North America.
After touring DMTN, DENSO North America CEO Kenichiro Ito (R) presents Ambassador Sugiyama with “Made in Tennessee” items to commemorate his visit.
Chuntao Ye (R) walks Ambassador Sugiyama through the warehouse process in Plant 302. OPTIONAL Behind the ambassador (L to R), Senior Manager Tom Cole; DMTN President Jack Helmboldt; DMTN Vice President Hidecki Ichikawa and Toyohisa Nakano, DMTN Executive Coordinator, look on.
Mike knows the definition of hard work. He lives it day-in and day-out. For him, hard works pays off; it’s the only way to approach the challenges life throws at you.
Mike started at DENSO as a temporary more than 11 years ago. He worked hard to show his chain of command that he wanted to be full-time, and that he could handle the responsibilities that came with that. Now, as a full-time production technician, Mike tries to lead by example and show others the value of hard work.
“As DENSO grows, and technology changes, we’re faced with so many challenges every day. Having to support first-hand with setting up new lines, I know how tough it can be. It’s always been my number one goal to ensure quality and integrity is never compromised during these crucial moments.”
Despite the challenges Mike has faced at work and personally, he challenges himself to approach every day with a positive attitude, and a willingness to make himself and his team better.
“DENSO has provided me with all the resources possible to be successful. This alone is my motivation to give back to DENSO. I feel that DENSO has molded me into the best employee I can be, and that’s why I want to give back and help others strive for greatness.
Hard work comes from within each individual. We must challenge ourselves, and others, to improve the quality of our products for our customers as we continue to grow. Hard work always pays off in life.”
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.
In the wake of Global President Arima’s New Year message, our teams are left pondering next steps, what we need to do to contribute to DENSO’s transformation. Chris Ramsey, senior manager of Business Planning at DENSO’s Maryville, Tenn., facility, is no different. But, at his core, he believes faith and courage are what he, and DENSO, needs to move forward.
Starting his career at DENSO more than 20 years ago and working his way up through Cost Accounting and Business Planning, Chris has seen a thing or two. And still, he says, “I believe in the future. I have faith in DENSO, and the people of this company, that we’re going to make a better future for the world.”
Chris shares this perspective having experienced tough times during his DENSO career:
“In 2009, when all was looking bleak from a business point of view, [DENSO] found a way to overcome. We found a way to keep our people employed, and found a new way for us to operate. We re-evaluated our operations, processes – everything. We became more competitive and stronger. Our people learned about themselves and what is really, truly possible.
“This is only one example that shows our associates are in it for the long haul – it’s not just a job at DENSO, it’s a way of life. There are a lot of different ways to make more money, but I don’t think that’s why people work here. We’re working for the people we’re with. We’re always pushing one another to find new ways to overcome challenges.”
For Chris, “faith” and “courage” go hand-in-hand.
“Courage means the courage to change, to be different, and to know when it’s time to be different and change. I believe we should question everything and not only do something because someone says we need to. Be true to your values and trust (have faith) in your potential. You have to be yourself.”
In 2015, executives asked a group of senior leaders at DENSO’s Maryville facility, including Chris, how they could improve their targets in quality, safety, cost, and delivery. Usually, a request like this is followed by a quick meeting, hurried action plan, assignments, due dates, follow-up meetings, and so on. Chris and other senior leaders decided to take a stand and put a stop to that routine. They wanted to truly dig into the core issues behind their targets.
After several discussions, the team concluded it was their mindset, their way of working, that caused them to fall short of their targets. Everyone worked in a silo. Each function was working toward their own goals, not trying to understand how they impacted other functions. It was a tough truth to face.
The team tackled it head-on. Through several discussions, off-site workshops and meetings, the group was able to break down barriers between functions and leaders. Chris recalled, “It wasn’t always comfortable, and it sure wasn’t easy, but, after 25 years of operation, Maryville’s leaders, from all our different areas, were starting to think and work more closely together.”
“Mr. Arima described this time as the second birth of our company. There are many ways to feel about that, most are probably scared or excited. We have lots of things to be concerned about – huge shifts in the mobility market, consumer habits, new competitors, and more. I believe faith is necessary because faith in this sense means we must believe in our potential. It’s not an option for us to move forward without faith in ourselves and each other. If our future is to be, it’s up to us to make it happen, and I have faith that we will all do what’s necessary to achieve our future potential.
“To make the future happen not only takes faith, but also courage. Courage is not the absence of fear, but doing what’s needed in spite of it. If we don’t have a sense of fear or crisis then we are not being realistic. However, we cannot be lead or paralyzed by it. We must press on. Find new paths, fail fast and learn fast. The future of DENSO depends on how fast we can fail and learn and our courage to keep doing both.”
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.
DENSO Spirit has been our guiding principles, the foundation, behind our innovation, quality, determination, and customer focus over the past 70 years.
As DENSO has grown to more than 170,000 people, 220 facilities, operating in 35 countries and regions around the world, we have drifted from our spirit.
In his New Year message, President Arima challenged: “Because we are busy, are we missing our foundational spirit? Are we avoiding risks?”
To achieve our long-term policy goal, and lead a transformation in the automotive industry, Arima challenges associates to go back to our spirit – strengthen our understanding and practice of our guiding principles. He redefines the DENSO Spirit values to help bring them to life for associates:
“‘Thinking things through’ means identifying the deeper meaning behind the issue, not just looking at the surface. I want you to think, think and think through with a future-oriented view,” Arima said. “The more you think, the more you see what you should do.”
“When we gather our individual power, we can maximize our performance, make changes and keep on challenging.”
“When you find what you should do, then get things done. The bigger dream you have, the bigger challenge you will face. You are the owner of your dream. It is your job.”
Watch videos on how our Mexico team is thinking things through, coming together and getting things done.
“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.
Congratulations to DENSO Mexico for earning top honors as the number one Excellent Factory (EF) in North America! We’re sharing perspectives from DENSO Mexico’s ICT plant throughout the month to learn more about DNMX’s journey to excellence.
This week: Adrián Rosas, TIE Manager, on what’s next for DNMX EF
“This last year, we sought to do something different: Getting the people themselves to develop their fellow workers. This was one of the points that helped us revolutionize the activity that we were already carrying out. It was a trigger, a key point, for winning this competition.
It’s always an honor to travel to represent Mexico and, obviously, DENSO, in this global conference, to see how representatives of other plants around the world had this opportunity and, above all, to share experiences that allow you to understand the situation at other companies and to see how other associates address their challenges.
What’s the next step? We’re seeking to balance the three plants in Mexico, to be the best on a national level. With the effort and dedication that our Associates bring, we will go very far.”
Congratulations to all those who competed at 2018 NAQCC and good luck to our award winners at the global competition this month!
Congratulations to DENSO Mexico for earning top honors as the number one Excellent Factory (EF) in North America! We’re sharing perspectives from DENSO Mexico’s ICT plant throughout the month to learn more about DNMX’s journey to excellence.
This week: Leticia Orozco on improving productivity
“The satisfaction from completing a project of great magnitude is gratifying.
“We implemented a better production system, with improved productivity. We focused our activities to address productivity and cycle times. After analysis, we realized how much MUDA (wasted time) of our team we had, and worked together to shift our focus and make our time at work more productive.
We accomplished this through strong teamwork. It was certainly a major achievement to complete after six months. It makes us very proud to know we are making a big contribution to the company, and this will be reflected in our work.”
This was just one of the processes that underwent considerable improvement, and it was an important part of how the ICT plant in Apodaca won the EF award at the regional level, competing with plants like DMMI and DMAT.
DENSO Mexico’s enthusiasm, dedication and creativity to kaizen shine every year at the North America Quality Circle Competition (NAQCC)*. Boasting a winning team for the last 10 years, DENSO Mexico (DNMX) didn’t disappoint this year with Team Hybridos achieving the Benchmark Award, the highest honor at the NAQCC event. Taking home the top honors allows Team Hybridos to move on to the next level in the kaizen competition, representing North America in the global competition in Japan next month.
Team Hybridos focused on reducing the LSH (linear solenoid) control pressure defect often found during the inspection process. The process was analyzed in close collaboration with DENSO Japan. As the team was implementing countermeasures, they unearthed another leakage defect and were able to tackle that issue too! In the end, both defects were eliminated, in turn improving KPIs for inspection defects, scrap and operation ratio.
While the team made significant improvements to DENSO’s overall quality and business operations, they walked away with individual successes as well:
“With this competition, I was able to move past my fear of public speaking. I now know that I’m capable of doing it, with confidence.” – José Jair de Jesús Jacques Luevano
“My favorite part was getting to know the other teams. We formed a strong bond with other participants. Everyone was able to put the competition aside for a moment and enjoy each other’s company, and get to know one another better.” – Arturo Josue Corzo Figueroa
“This was an experience of a lifetime. I was proud to represent my company and achieve such challenging targets. These were unforgettable moments.” – José de Jesús Facio Mares
Congratulations to Team Hybridos!
Arturo Josue Corzo Figueroa (PE Valve Body)
José de Jesús Facio Mares (Valve Body)
María Guadalupe Resendiz Resendiz (Valve Body)
José Jair de Jesús Jacques Luevano (Valve Body)
Antonio Gonzalo Zuñiga de León (Valve Body)
Get to know the team
Our people are the core of everything we do – our commitment to safety and quality, our drive to develop innovative products and give back to our communities. Our success comes from our associate’s diverse talents and strong passion.
Click here to learn more about the people behind Team Hybridos, what motivates and drives them every day.
*What’s NAQCC?
NAQCC is the North America Quality Circle Competition, a regional competition for DENSO’s top quality circle teams to demonstrate their skills in team building, leadership, computer knowledge, public speaking, and problem-solving. Quality circle teams consist of a group of associates, working together to identify, analyze and solve work-related problems. DENSO has thousands of quality circle teams across the globe, helping DENSO reduce costs, increase quality, efficiency and safety, and preserving and protecting the environment.
Congratulations to DENSO Mexico for earning top honors as the number one Excellent Factory (EF) in North America! We’re sharing perspectives from DENSO Mexico’s ICT plant throughout the month to learn more about DNMX’s journey to excellence.
This week: Enrique Treviño, Senior Vice President, on the human side of EF
“EF is an overall activity of the plants. It comprises various subsystems. We can think of it like a gear assembly. Seeing it function, it looks simple; making it work is the real challenge. This has been worked on for years. For C&C, taking part in the competition is not new; it has been a contender before. The results that we saw this year is the accumulated work of years of structured progress and teamwork.
The most important thing is to have the necessary knowledge of the tools that are used in order to have an efficient plant, and for personnel to understand them so that they can prevent and solve problems effectively.
One important part of having received this award was the full involvement of our personnel. Doing Kaizen with the participation of all — that is the human side of EF.
EF Developers have the task of developing knowledge of this technique so that everything will work based on the guidelines required to be an efficient plant; that differentiated us from North America. I am very proud of all the people involved, because we have shown once more that DENSO Mexico has the capacity to go very far. Congratulations!
DENSO Manufacturing Canada Corolla ECM Team achieves 10 years perfect quality
Congratulations to the Toyota Corolla Engine Cooling Module (ECM) team at DENSO Manufacturing Canada for reaching a milestone of 10 years perfect quality for supplied parts to Toyota Manufacturing Canada!
For DMCN, this was the first time manufacturing this product type, and there was an excellent opportunity for a strong product launch. We needed a different approach to strive for perfection, this started with the people.
Hear from some of the team members who made it happen:
Associates were selected well in advance of launch and took part in the development of process flow, standardized work, and assembly cell setup. This preparation was DMCN model activity for monozukuri (‘the art of making things’) which included full involvement and integration of associates who would challenge the status quo, and each other daily to ensure a strong Quality focus and process ownership.
This performance, coupled with an unrelenting desire to continuously improve, has resulted in Perfect quality and is now the longest period of time without a customer claim in DENSO globally.
Over the years, the faces may have changed, but the firm commitment to Quality Perfection has continued and the baseline has now been set for future achievement.
Thank you to all the teams who helped us achieve 10 years perfect quality!
Congratulations to DENSO Mexico for earning top honors as the number one Excellent Factory (EF) in North America! We’re sharing perspectives from DENSO Mexico’s ICT plant throughout the month to learn more about DNMX’s journey to excellence.
This week: Roberto Munguia, TIE specialist, on overcoming challenges
“In each project, there are different challenges we face, and we have to know how to overcome them.
We worked on improving productivity through something called ‘Fractional Manpower.’ This is implemented in various ways, such as transferring people, to create a balance and improved productivity.
Our biggest obstacle was time. We wanted to start making changes on a certain date, but, at the same time, this was a major line-modification activity. It wasn’t a simple task. It required bringing together many departments such as support, engineering, production, logistics and others, and coordinating various departments in order to monitor KPIs since everyone has their own. However, together, we were able to successfully overcome this challenge, in a record two month time!
Human Development was also an important piece in the process, because we were working hand in hand with the production team leader. We learned a lot about Fractional Manpower, and how this could be applied to different areas of the company.”
This was just one of the processes that underwent considerable improvement, and it was an important part of how the ICT plant in Apodaca won the EF award at the regional level, competing with plants like DMMI and DMAT.
Congratulations to DENSO Mexico for earning top honors as the number one Excellent Factory (EF) in North America! We’re sharing perspectives from DENSO Mexico’s ICT plant throughout the month to learn more about DNMX’s journey to excellence.
This week: Nancy Castillo, PC supervisor, on a culture of continuous improvement
“When we enjoy what we do, it stops being work.
Since the first time DENSO Mexico won the award for best EF activity, plans have been increasingly high-level and challenging for everybody. Over these last years, we have succeeded in defining unique and innovative activities. However, we need to accelerate our actions in order to be able to remain competitive.
We realized that the sustainability that we needed would be achieved only with the help of the people who work in each process, from the ground up: the EF Developers — people with knowledge and who have a passion for improvement.
EF Developers are the beginning of a culture of continuous improvement, where not only knowledge is sought, but also their actions motivate people to strive for more.
It was an honor to be part of this and, with DENSO Mexico, to win the EF award for North America.”
Earlier this month, associates drove a Lexus RX equipped with DENSO’s Advanced Driver Assistance System (ADAS). The active driving system can take over a vehicle and assist in avoiding traffic accidents, should a driver be distracted. Associates drove the vehicle at 15 mph toward a target and within seconds, ADAS stopped the car and protected the passengers.
The event showcased the impact of quality for associates and showed first-hand how producing a quality product plays a critical role in the future of mobility.
Hear what associates had to say about their experience:
In September, 23 Quality Circle teams* crossed state and country lines to gather in the “windy city” of Chicago for the 2018 North America Quality Circle Competition (NAQCC).
After several months of research, problem solving, testing and troubleshooting, teams showed off their unique kaizen ideas and personalities through eye-catching, dynamic presentations.
The trip wasn’t all work. Every NAQCC event incorporates an associate engagement activity, such as just-for-fun team building activities or community service activities to help break the ice and get teams talking, laughing and energized. This year featured “minute to win it” games on the first night. Teams also assembled, in a strategic competition, more than 500 First-Aid emergency supply kits for the American Red Cross, one of DENSO’s long-time community partners.
Shout-out to the teams
Quality Circle teams are the energy and drive behind DENSO’s “quality first” and kaizen mindset. They play a huge role in pushing our company to continuously improve and reach new heights. Thank you to this year’s teams for leading the way!
DENSO BROS, NAPIC
THE LAB MONKEYS, DMAT *Effort Circle Award Winner PLASTILINA, DNMX *Judges’ Circle Award Winner TOO COLD TO FLOW, DMMI GAMECHANGERS, KDMK STATOR TEAM, HDMX GUARDIANS OF THE SOLDER BLOCK, DMTN THE TRAINABLES, ANC LOS HIJOS DE BONICE, DNMX *Productivity Circle Award Winner MILLERSAPS AND FRIENDS, DMTN ACME KAIZEN COMPANY, DMAT THE INNOVATORS, DMCN |
SEPARATE WAYS, DMMI
STRAIGHT OUTTA LONG BEACH, DPAM POWDER BE GONE, GNC HYBRIDOS, DNMX *Benchmark Circle Award Winner FOR THOSE ABOUT TO WALK, DMAR T-N-T: TODAY NOT TOMORROW, DMAT *Safety/Environment Circle Award Winner LOS IMPLACABLES DE LA CALIDAD, DNMX *Quality Circle Award Winner LEAN MACHINE, DPAM EMOJI TEAM, ASMX CAN’T CUT THIS, DMMI SIX PACK, DMTN *President’s Circle Award Winner* |
Representing North America
Congratulations to Team Hybridos from DENSO Mexico, and Team Six Pack from DENSO Manufacturing Tennessee, awarded with the top two highest honors at this year’s regional competition. These teams will represent North America in the global competition in Japan in November!
Below is a sneak peek of all the fun at the 2018 NAQCC. Stay tuned for more stories and videos coming soon!
*What’s a Quality Circle?
At DENSO, we seek continual innovation in manufacturing to ensure consistent high-quality products, safe working environments and reduced environmental impact. That’s why Quality Circle or kaizen teams are an important part of our daily working lives. Quality Circle teams consist of a group of associates, working together to identify, analyze and solve work-related problems.
The first North American Quality Circle team was established in 1987 at DENSO Manufacturing Michigan Inc. Today, we have thousands of Quality Circle teams across the globe, helping DENSO reduce costs, increase quality, efficiency and safety, and preserving and protecting the environment.
Quality Circles also provide a hands-on learning experience for associates to develop many skills, including team building, leadership, organizational, computer knowledge, public speaking, and problem-solving. Plus, teams have the opportunity to travel and show-off their creative kaizen solutions.
Congratulations to DENSO Mexico for earning top honors as the number one Excellent Factory (EF) in North America! We’re sharing perspectives from DENSO Mexico’s ICT plant throughout the month to learn more about DNMX’s journey to excellence.
This week: Maricela Puente, team leader of final assembly, on the EF Developers’ Program
“You learn something new with each challenge, even more so when you work in collaboration with other areas. In the EF projects, various pillars are developed, each group has a different focus. We focused on the standardization Kaizen.
With associates in my area, we implemented the EF Developers’ system, which consists of developing personnel (in this case, line personnel) and carrying out a system for the correct use of tools, as well as the proper process for auditing and detecting, in a timely manner, an area that requires Kaizen, so that we will have time to implement impactful improvements. All of this is being implemented in ICT at the Apodaca, Guadalupe and Silao plants.
I began alone in TAE, and then I began with very small Kaizen improvements. Those small improvements led me to create larger improvements and ideas, and altogether, a significant impact.”
This was just one of the processes that underwent considerable improvement, and it was an important part of how the ICT plant in Apodaca won the EF award at the regional level, competing with plants like DMMI and DMAT.
Our commitment to monozukuri, “the art of making things,” is a strength DENSO has nurtured since its founding. It has led to many of our unique manufacturing processes and world-first products. But, in true DENSO fashion, we’re looking to continuously improve and take monozukuri to the next level. One way we’re moving in this direction is through the Excellent Factory (EF) activities.
What is “Excellent Factory”?
EF activities are aimed to continuously improve production sites by involving all associates at the plant – from the leadership team to front-line production associates – it’s a cross-functional, collaborative effort.
DENSO challenges plants and recognizes top EF activities at its annual DENSO Group EF Activity Conference. This year, teams from DENSO Mexico, DENSO Manufacturing Michigan, and DENSO Manufacturing Athens Tennessee were awarded in our regional EF competition. Being recognized with top honors, DENSO Mexico was invited to share their activities at the Global EF Conference in May.
What’s it take to be named EF?
Four main pillars are evaluated for EF honors:
Top Honors for DNMX ICT Plant
ICT associates made several improvements across the plant to exceed in the main EF pillar categories. However, the EF Developers’ program helped DNMX really stand out against the competition and take home top regional honors.
The EF Developers’ program is a training program. Group leaders train their colleagues on correct use of tools, as well as the proper process for auditing and detecting, in a timely manner, an area that requires Kaizen. This allows time for teams to make impactful improvements.
“One important part of having received this award was the full involvement of our personnel,” said Enrique Trevino, vice president of DENSO Mexico. “Doing kaizen with the participation of all — that is the human side of EF. EF Developers have the task of developing knowledge of this technique so that everything will work based on the guidelines required to be an efficient plant. That is what differentiated us from North America. I’m very proud of all the people involved, because we have shown once more that DENSO Mexico has the capacity to go very far.”
All they do is win!
Congratulations to DENSO Mexico for earning top honors as the number one EF factory in North America! This is the third time DENSO Mexico has been distinguished with top honors, making DENSO Mexico the company with the most EF activity awards since the start of the competition in North America.
Stay tuned throughout the month to learn more about DENSO Mexico’s EF activity and the associates who helped make it happen.
At DENSO, we are always looking for motivated, collaborative, eager, and dedicated individuals to join our team. Ronnie Sturgeon is a perfect example.
Ronnie was hired at DENSO Manufacturing Michigan Iowa through a temp agency as a part-time production assembly associate. The job required him to build modules, meet deadlines, work closely with a small team, and self-motivate.
While Ronnie did not have a strong background in manufacturing, his references raved that Ronnie always gave 100 percent, took on any jobs with enthusiasm, went above and beyond what was expected and had an incredibly positive attitude. Ronnie was well-prepared for the interview, reading up on DENSO, our high-quality standards, our vision for future mobility and the part he would play in helping us achieve that.
After a few short weeks at DENSO, Ronnie received an “Employee of the Quarter” recognition from his temp agency and is now being hired full-time by DENSO.
“It’s exciting to know that I will be a full-time employee and part of the DENSO family,” said Ronnie. “The benefits are incredible, and the production team is awesome to work with. I look forward to growing with DENSO and incorporating the skills I learn in my job and using them to further my future as a DENSO employee. It’s exciting to know that DENSO provides many opportunities allowing you to continue your education which is a great employee investment and a great opportunity.”
Ronnie, who plans to get his associate degree in Tool and Die, is a shining example of someone who is crafting his career at DENSO.
DENSO, and our affiliate Michigan Automotive Compressor Inc. (MACI), were honored as top-performing global suppliers for Ford Motor Company at the 20th Annual World Excellence Awards. Only 30 companies were selected as finalists from thousands of Ford suppliers globally.
“I would like to extend my personal congratulations to DENSO and its associates, the entire MACI team and the Ford sales team for achieving this award. At DENSO, our core focus is producing and developing high-quality, innovative products and technologies that address the changes happening within the automotive industry while exceeding customers’ expectations,” said Thomas Esser, vice president, Global Ford Sales, DENSO.
DENSO was awarded Ford’s World Excellence Award for Quality. MACI was recognized for the third time, receiving the Gold World Excellence Award for excelling in the categories of Cost, Quality, and Delivery. MACI manufactures automotive air conditioning compressors with magnetic clutch for Ford and other customers like Honda, GM, Chrysler and Toyota. As the main component of the air conditioning system, MACI’s compressors play an integral role in keeping drivers and passengers comfortable in warm weather.
“Every associate in MACI works toward one goal – to satisfy our customers,” said Joe Shaughnessy, General Manager, Business Planning, Human Resources, Information Systems, Production Control at MACI. “This is our top priority. It is so gratifying to receive such an elite award that recognizes our team’s collective efforts.”
About Michigan Automotive Compressor Inc.
Established in 1989, Michigan Automotive Compressor Inc. (MACI) is a joint-venture between Toyota Industries Corporation (TICO) and DENSO Corporation. It is the largest manufacturing employer in Jackson County, with over 1 million square feet, and more than 1,050 associates. MACI sells approximately 6 million compressors of all types each year, for many of the world’s most popular vehicles. GM and FCA-Chrysler are the largest customers by volume. Ford, Toyota, Honda, Freightliner and John Deere also are customers.
Competing in manufacturing often means figuring out ways to outdo yourself. So when our multicooler engineering team investigated how to improve and reduce costs on jumper pipes, they began thinking outside of the box – and pipe.
Our own Afsheen Mozammel, a senior processing engineer, is part of the team recognized for ushering in massive changes to the mass production process, which resulted in significantly lowering the cost and number of products used in securing these unique condensers. By brazing the pipes, associates use less time driving-in screws (8 less screws, to be exact) and can more efficiently weld or crimp on new extruded metal brackets before brazing.
When the 2019 model year multicoolers start rolling off our assembly lines, the estimated savings are up to $3.3 million per year. Thanks to Afsheen and her team, DENSO is saving both time and money one jumper pipe at a time.