Manufacturing Excellence Manual

GK Eagan 7/09/14

Rev. #10

Table of Contents
The Goal of Manufacturing Excellence:....................................................................................................................2
Program Description:...............................................................................................................................................2
Quality System Connection:.................................................................................................................................2
Responsible Care Management System (RCMS) Connection:..............................................................................2
Outline of Major Components:.............................................................................................................................3
The Seven Elements of Manufacturing Excellence:..............................................................................................3
Management Responsibilities:.............................................................................................................................3
The Goal Achievement Process:...........................................................................................................................4
Key Success Area (KSA) Champion Responsibilities:.................................................................................................5
The Managing Process:.........................................................................................................................................5
Table #1: Champion Responsibilities & Metric Reporting Sources.......................................................................5
How Champions Accomplish:...............................................................................................................................6
Employee Role:.........................................................................................................................................................6
Communications Plan:..............................................................................................................................................7
Goal:..................................................................................................................................................................... 7
General:................................................................................................................................................................7
Format of Weekly KSA Meetings:.........................................................................................................................7
Monthly Reports:.................................................................................................................................................7
Documentation:...................................................................................................................................................7

1
The Goal of Manufacturing Excellence:
1) Focus on Excellence in Manufacturing to Support the Continuous Improvement of Niacet Results in
Achievement of Company Vision and Goals
2) Improve Employee Performance and Satisfaction Through the Development of People
3) A Focused Management System as a Resource to Facilitate Niacet Growth

Program Description:
Manufacturing excellence is a goal setting and achievement management system aimed at proper development
of goals and the facilitation of employee success in achieving those goals while succeeding personally and
professionally. The program supports the Company vision through the following hierarchy:

1) Corporate Vision
2) Company Charter
3) ISO9000:2008
a) Quality Policy
b) Annual Quality Objectives
4) RCMS
a) RCMS Policy Statement
b) Annual RCMS Goals
5) Manufacturing Excellence

Quality System Connection:

Manufacturing Excellence supports Niacet’s ISO9000:2000 Quality System in terms of being a management
process intended to help employees succeed in fulfilling Niacet’s Quality Policy and achieve related Annual
Quality Objectives.

Responsible Care Management System (RCMS) Connection:

Manufacturing Excellence supports RCMS in terms of being a management process intended to help employees
succeed in fulfilling Niacet’s RCMS Policy and achieve Annual Objectives.

2
Outline of Major Components:
1) Seven Key Success Areas With Effective Measures
2) A Champion for Each Key Success Area
3) Measures with GAP Analysis
4) SMART “Key Initiatives” as a function of priorities and resources:
a) Specific
b) Measurable
c) Achievable
d) Relevant
e) Time Based
5) Prioritized Projects as a Function of Resources
6) Project Plans with Resources
a) Who
b) What
c) When

The Seven Elements of Manufacturing Excellence:

1) Production Capability
2) Quality
3) Cost
4) Safety
5) Environmental
6) People
7) Capital Effectiveness

Management Responsibilities:
1) Assign Champions for Each KSA
2) Establish Measures for Each KSA
3) Establish Key Initiatives
4) Establish Improvement Project Priorities Through Proper Alignment of Program Results with Corporate
Vision.
5) Provide Resources to Achieve Goals

3
The Goal Achievement Process:

4
Key Success Area (KSA) Champion Responsibilities:
The Managing Process:

Table #1: Champion Responsibilities & Metric Reporting Sources

Key Success Area (KSA) Champion Measure Reporting Responsibility & Source
Safety DJ Demmin SJ D’Angelo through the Monthly Quality/ Regulatory Report
Quality DP VanKerkhove SJ D’Angelo through the Monthly Quality/ Regulatory Report
Production Capability TP Kolb Operations Managers through Monthly Reports
Operations & Facility Managers through Monthly Reports and
Cost GA Kandow
Monthly Financial Reports
People GG Stewart Operations & Facility Managers through Monthly Reports
Environmental AF Abaya SJ D’Angelo through the Monthly Quality/ Regulatory Report
Capital Effectiveness DM Hale DM Hale

5
How Champions Accomplish:
1) Teamwork is Crucial to the Success of All - Facilitate Others
2) Continually Seek Alignment of Goals with Business Objectives - Stay on Goal, Not Necessarily On-task
3) Maintain Niacet focus on the Key Initiatives:
a) Develop and use measures to track progress:
i) Set up a system so that measures are kept by the appropriate people and flow to you each month.
b) Work with the Mfg. Leadership Team, Dir. Of Manufacturing, Operations & Facility Managers:
i) Monitor project progress
ii) Assess needs for changes to the plan to meet the Key Initiative goals
c) Work with the Project Leaders:
i) Monitor resource needs
ii) Advocate for obtaining those resources
4) Ensure that KSA status is reported consistently and regularly:
a) Work toward consistency of format in the monthly reports:
i) Fit all important work in each report into the appropriate KSA
ii) Monthly reports should reinforce the Manufacturing Excellence system
b) Lead the monthly Manufacturing Excellence meeting for your KSA:
i) Use these reporting meetings to communicate progress across the plant site.
ii) Ensure that the individual reports cover the key information needed by the owners to monitor and
evaluate progress against the Key Initiative Goals.
iii) Manage the agenda to ensure that the timely and important messages on each KSA are covered
(resource needs, changes in plans to ensure the goals are met, and key accomplishments)
5) Ensure that Successes are Recognized and Celebrated where appropriate:
a) Ensure that individual engineers and others who play key roles on projects get the opportunity to be
recognized by reporting what they have done at the meetings.
b) Catch people doing things right! Include a “Wins” Slide
6) Work to address fundamental challenges which impeded success in the KSA overall at the root cause level:
a) Include a “Challenges” Slide

Employee Role:
Help Develop and Implement The Niacet’s Goal Achievement Process

1) Develop Key Initiatives in Each Key Success Area

2) Develop and Implement Project Plans - Who does What by When
3) Achieve Results
4) Be Successful:
a) Understand Niacet’s goals
b) Understand your job, your goals and your required action steps
c) Communicate your ideas and needs
d) Measure and communicate your progress
e) Help others be successful
f) Develop the skills you need to succeed
6
Communications Plan:
Goal:
1) Improve Communication At All Levels of Our Organization to Improve Opportunities For
Success
2) Provide Increased Opportunities for Employees to Showcase their Successes

General:
1) Champions as Project Managers using PowerPoint Project Summaries
2) Measures reporting to feed into management reports
3) Use of a “Manufacturing Excellence Score Card”
a) Summary Page with Green / Red Indicator
4) Accomplishments achieved through Manufacturing Excellence are an important part of employee
Performance Evaluations

Format of Weekly KSA Meetings:

1) All Operations Level Managers and Production Engineers Participate, Special Guests Requested
2) Focus On Updates To Key Initiative Projects
3) Summary Presentation of Results Are By the Project Leader:
a) The Meeting is Not the Place to Solve the Problem
b) Status is Supposed to Be Current Going Into the Meeting
4) Meeting is Managed By the KSA Champion
5) Deliverables Include:
a) Meeting Agenda Including Project Updates, Issued 24 Hrs Prior To Meeting.
b) Meeting Notes, Issued Within 48 Hours Of The Meeting.
6) Includes Budget Where Applicable

Monthly Reports:
1) Issued No Later Than the 7th Day of Every Month
2) Includes:
a) Key Success Area Measures
b) Much of the Current Decision Making Basis Information and Analysis

Documentation:

1) Stored on Z drive
2) All measures and data tracked in SAP or Other Company Reporting Systems