Issue 71: Fall 2011 – Shape on the Roll (, 5mb)
Transcription
Issue 71: Fall 2011 – Shape on the Roll (, 5mb)
Make Great Parts. Be Fair. HAVE FU ISSUE 71 FALL 2011 Shape Culture at Work STOP. LOOK. LISTEN. Pedestrian Protection Pg. 14 PLAYING WITH A PURPOSE SPS Workshop Pg. 18 Included: • Update from the CEO • Business Unit Updates • After Hours Like Us on FACEBOOK Discover Shape Online New Website on ROLL FORMING Discover Shape Online facebook.com/shapecorp shaperollforming.com 18 14 12 CONTENTS FALL 2011 Gary Verplank Chairman of the Board Cover: From outdoorsman to techie to biker, the Shape leadership team is full of fun and unique personalities. Caricatures by Drake Schaberg. 1900 Hayes St. Grand Haven, MI 49417 616.846.8700 www.shapecorp.com EXECUTIVE CONTRIBUTORS Executive Update Business Unit Updates Shape Online Lending a Hand Locally After Hours 10 Constructing Relationships 12 Culture and Values NEW OPPORTUNITIES THE SHAPE BUNCH 14 Pedestrian Protection STOP. LOOK. LISTEN. 16 Pedestrian Protection COUNTERMEASURES THAT SAVE LIVES 18 SPS Workshop GARY VERPLANK Chairman of the Board Shape Corp. JASON MEYER General Manager Chrysler/Fiat Business Unit ROB WEYKAMP Vice President GM Business Unit JACK RUSSELL Vice President International Business Unit JEFF PIPER Vice President Ford Business Unit JASON BRICKER Vice President Nissan/Renault Business Unit Don't see an update from a familiar face? Each issue of Shape on the Roll will feature leadership updates from alternating business unit and regional teams. Look for more faces and updates in the next issue! EDITOR / CREATIVE DIRECTOR CONTRIBUTORS Danni Schertzing [email protected] Scott Bacon, Chuck Dewitte, Jim Rosasco, Peg Buehler, Sandy Charon, Darla Crouse, Erica Meyer, Doug Peterson, Char VanderStel, Gary Verplank, Ed Pendergrass, Ashley Werner ASSOCIATE EDITORS Ashley Ingle [email protected] Sarah Heins [email protected] Drake Schaberg www.ekardstudios.com After moving to our new location in Grand Haven in 1979, Bob Currier Sr. began inviting associates to his house for a genuine lobster boil. Everyone came together for the feast and helped cook the large lobsters. Around this time we also began the tradition of giving turkeys to all associates for Thanksgiving, and former Shape President, Pete Sturrus, dressed up as a pilgrim to highlight the distribution. Following in the tradition of fun and feasts, some tool and die makers (many of whom were from Robinson Township) and Richie Heinz started the tradition of the "Robique" (a Robinson Township BBQ). We had a great time cooking everything under the sun! This tradition lasted for many years, until we were forced to remove all cooking appliances from the tool rooms. We had a Christmas party every year, until our employment size became so large that we could not find a facility to handle the event. So we began a new tradition – a summer picnic and celebration. Over the FIND SHAPE CORP. ONLINE www.shapecorp.com www.shapepedestrianprotection.com www.shaperollforming.com PLAYING WITH A PURPOSE www.facebook.com/shapecorp 2 CARICATURE ILLUSTRATIONS BY Through these commitments we have created a culture and an atmosphere where we can enjoy the company of our associates and have some fun. Here are just a few of the stories… www.youtube.com/watchshapecorp 2010 — Shape Summer Party, Muskegon, Mich. years we have enjoyed the Muskegon air show, Michigan Adventure Park, Muskegon’s Summer Celebration and being aboard the LST ship. With all of the fun we have each year, we look forward to continuing this tradition. Associates are rewarded each year for perfect attendance. One year, associates were allowed to shoot a bow and arrow at Tom DeVoursney and I as we ran in front of them. Needless to say, this reward activity did not become an annual tradition. Supporting the community through efforts such as raising money for United Way and Hospice, is another way we have fun at Shape. To encourage associate participation, we have had unique incentives for meeting or exceeding our yearly United Way campaign goals, such as allowing people to dunk their favorite associate in a tank or throwing pies in their faces. The culmination one year was having President, Tom DeVoursney allow us to shave his head when we met our goal. For Hospice fundraising we have enjoyed having, former HR manager, Mary Postmus dress up like a duck. One of the most beloved traditions at Shape is the Easter Breakfast on the Saturday before Easter, where all of our children and grandchildren join us. EXECUTIVE UPDATE FALL 2011 SHAPE CORP. WORLD HEADQUARTERS 3 4 9 20 22 HISTORY OF FUN From the earliest days of our founding in 1974, Shape has been committed to satisfying our customer relationships and to the well-being of our associates. CONTACTS CONTENTS Tom DeVoursney Shape Corp. President EXECUTIVE UPDATE 1984 — HR Manager, Mary Postmus poses with the Bunny at Shape's Easter Breakfast. In 1993, we funded the Fitness Factory, to promote wellness for our employees. Fun fitness events have been introduced since, such as starting golf league, sponsoring an indoor bicycle ride and hosting summer camp for our kids. 2009 — President, Tom DeVoursney shaves his head after company exceeds United Way campaign goal of 90% company participation. On our 25th anniversary in 1999, we had a great picnic and initiated our Giving Back program. We sent 800 employees into various communities to do volunteer work for an entire day. This tradition continues and has become a tradition for many other companies in our area. We have always believed that our associates at Shape Corp. are our most valuable asset. If we are to continue our success and foster growth, the cooperation and efforts of all of our associates is essential. We have always felt that traditions and fun should be part of our culture and well-being. Thank you for making this a great place to work! Make Great Parts. Be Fair. Have Fun. Gary Verplank, Chairman of the Board 3 Jeff Piper Vice President Ford Business Unit GM BUSINESS UNIT UPDATE FORD BUSINESS UNIT UPDATE Every Monday morning, we like to take time to ask how each other's lives are going — what's happening with kids, pets and life. The old saying, ‘Work Hard. Play Hard.’ certainly holds true for the Ford Business Unit team. As a team, interestingly enough, we all share many common interests that allow us to connect with each other on a more personal level. I truly believe this helps us communicate better as a team and work together more efficiently. It also shows that we like to have a little bit of fun mixed in with our work. We have many sarcastic one-liners that we often repeat to one another and we tend to use humor to break up the day… we even have some fun nicknames within the team, and I think that’s what makes our team work so well together. We’re able to take the good with the bad; the fun with the work. WORK TO WIN ...this helps us communicate better as a team and work together more efficiently. It also shows that we like to have a little bit of fun mixed in with our work. Recently, we took our annual teambuilding trip to the Pere Marquette River for a kayaking and rafting adventure. We have some new team members this year, so we chose to draw straws for kayak partners. We met new people and got to know others better. We always have a great time floating or paddling, and it gets us out of the office and active. GM Supplier of the Year award presented to Shape by GM Director, Lloyd Gencay, Shape's 2010 Supplier of the Year award. In late summer, we held a Pedestrian Protection Expo at our Technical Center for GM employees to experience a hands-on approach to learning about Pedestrian Protection. The visitors had the opportunity to watch live impact tests related to Pedestrian Protection, and were able to examine a vehicle to see the implications the impact has on its exterior components. I’d like to take a moment to thank General Motors for their continued support. Receiving the GM Supplier of the Year award for the 10th year has made us proud to be a part of General Motor’s success. Thanks to the Shape associates who truly make a difference by producing great parts, on time, every day. Your dedication is what sets Shape apart. Another exciting event that took place was the GM Supplier of the Year Event. It was an honor to have GM come to Shape to present us with our 10th Supplier of the Year award. To show our Beyond rafting, the GM Business Unit has appreciation over the past several years, been hard at work with several new projects we have used the award presentation awarded and various customer visits. Shape as an opportunity to share a little of our manufactures the GMT900HD hitch, which “Shape fun” with our GM Business Unit has the highest towing rating in its class. associates. Each associate receives a We have also been awarded a new grille t-shirt, lunch and option to participate opening reinforcement (shutter body) for in the unique festivities. One year, we GM pick-ups and a roof rack for a new had a simulated race car, another year GM small SUV. The roof rack was a big there was a dunk tank, and this year—we accomplishment, being a two-shot molded played football. part, including both soft and hard plastic. 4 WORK HARD. PLAY HARD. Celebrating Shape's 10th GM Supplier of the Year award, the players from left to right: Former NFL / MSU runningback, Bobby Morse; GM visitor, Lloyd Gencay; and Shape associates, Tom DeVoursney and Bob Melvin. In late August, we had our 2011 strategic plan review. At the end of the day we decided to relieve some stress and have some fun by trying our hand at sumo tubing (both Kyle Verplank and I had lived in Tokyo and we wanted to compare the sumo tubing to the sumo wrestling in Japan). It was certainly a fun afternoon as evidenced in the pictures and I believe the team consensus was it was more fun watching than actually being in the tube. With the fun comes the work, and we’ve had many new projects launch over the past couple of months. We recently have been quoting active grille shutters for some Ford platforms and I am confident that Shape has the engineering expertise and manufacturing capabilities to provide value for products such as active grille shutters. These products complement our energy management and air flow expertise. In May, we visited Ford for a Pedestrian Protection Learning Day, where more than 300 Ford employees attended to hear Shape share its knowledge on the evolving global regulations and the available countermeasures that meet them. Shape associates presented eight seminars on various Pedestrian Protection topics to dive deeper into a few key topics. Due to the popularity of the event, we have launched several projects and in late August, we sourced a Pedestrian Protection energy absorber for the Ford Mustang, which we found to be very exciting. Keep your attitude willing and have fun when the time is right. I would like to send a very special thank you to the team for your hard work and continued support as we grow in new industries such as Pedestrian Protection. Your patience and ability to work as a team is key to providing successful products for our customers, but don’t forget to keep your attitude willing and have fun when the time is right. BUSINESS UNIT UPDATES FALL 2011 BUSINESS UNIT UPDATES FALL 2011 Rob Weykamp Vice President General Motors Business Unit Tom Bonnema (top) and Jeff Piper (bottom) get a "kick" out of the inflatable SumoTube during the Ford business unit's summer teambuilding event in Spring Lake, Mich. "Walk like a Pedestrian." Ford Motor Co. Product Development Engineer, Mohan Kamath, and Shape’s Ford Business Development Leader, Mark Liberatore, pose by a cutout of a pedestrian they named "Ped-ro" at the Ford Pedestrian Protection Learning Day in May. 5 Jack Russell Vice President International Business Unit CHRYSLER / FIAT BUSINESS UNIT UPDATE INTERNATIONAL BUSINESS UNIT UPDATE A WINNING TEAM TRANSLATING THE FUN The recent merger of Chrysler and Fiat has given Shape the opportunity to combine synergies and take advantage of our expanding global footprint. As we continue to expand our global footprint at Shape, we are also extending our Shape culture to our family members around the world. For the first time, we have a Shape associate based out of Turin, Italy in order to support our relationships in Europe and to leverage the new capacity of Shape Europe. Marcello Fassino is taking on the role of product development engineer and his past experience in working with suppliers will benefit Shape and Chrysler. Come October, our Shape Japan teammate, Tadashi Chikami, will personally experience the “Shape Family Culture” in Grand Haven. working the typical 8-5 schedule, we’re sometimes able to get out of the office and operate together in an outside setting. Marcello was able to make new associate connections and learn about the different roles within our team. We had a great time with Marcello and we can’t wait for him to visit again soon. From a manufacturing perspective, the Shape team has been working on several new initiatives to drive cost out of our value stream. We’ve created a dedicated team of engineers, processing specialists and program team members to analyze several areas of manufacturing and part design. Recently, we hosted a team from Chrysler to help facilitate an event that created dozens of new ideas. We’re With our new plant in Europe and Chrysler’s thankful for the team’s involvement an expanding global footprint, I am confident opportunity for Shape to share our ideas. in Shape’s ability to help implement their global programs successfully, both in I am happy to welcome our new team technology and manufacturing. members—Marcello Fassino, Dan Ralston, Bob Salmon, Brooke Eldridge Last month, Marcello Fassino was in and Matt Kuipers. We’ve had a lot Grand Haven for training and he was able of transition in our business unit as to participate in our annual teambuilding Chrysler ramps up with several launches. community service event. The team went To support these launches, we’ve to Muskegon Catholic High School to increased the number of engineers and make upgrades to their football field and new program managers. Our associates to landscaping. It gave us time to bond are really the ones who make the with our new teammate and it helped difference and ensure quality parts are Marcello learn a little bit more about delivered ontime and customer service Shape’s corporate culture. We were able levels remain high. Thank you for your to show him that rather than always hard work and dedication to the team. Tadashi works in our Shape Japan Toyota City office as a product development engineer and will be moving his wife, Atsuko, and daughter, Miyu, to Grand Haven to live for the next 18 months. Although he’s visited the United States on several occasions, living here will be quite a cultural experience…. I am confident in Shape’s ability to help Chrysler implement their global programs successfully — both in technology and manufacturing. 6 Members of the Chrysler Business Unit landscaped the football field at Muskegon Catholic High School. Top photo, left to right; Bob Salmon, Marcus Ashmore, Marcello Fassino, Dan Ralston, Kara Riemersma, Bob Harsha and Jason Meyer. Middle photo; Marcus Ashmore. Bottom photo; Bob Harsha, Kara Riemersma and Bob Salmon. Special thanks to Bruce Chase (not pictured). It’s likely that Tadashi will figure out that the sight of snow in your driveway can literally make you sweat when you look out your window on a winter morning. His very own teammates are going to be pulling at him from every direction to get him to become a fan of their favorite college football team. Heath Bedford may be telling him that Sparty is the best mascot he’ll find in Michigan, or Tom DeVoursney might teach him the Notre Dame fight song in an effort to reel him in. Someone may even go as far to gift Tadashi a Detroit Lions t-shirt to convince him they are actually a good NFL team to root for and certainly better than the Cleveland Browns. Unless he talks to Dave Reierson…who will do everything he can to convince him that hockey is the only sport actually worth watching. Tadashi will find that personal life achievements are a big deal at Shape. Your work anniversary, birthday or births of children are something we like to celebrate as a group….over donuts, cake or cookies, which you bring in yourself (and if you don’t, you’ll never hear the end of it). And lastly, you just might get some strange looks from your other Shape teammates if you decide to walk around without your shoes on. But, in all seriousness, we are very fortunate to have Tadashi come to work in Shape Grand Haven for the next 18 months. His contributions to Shape will continue to make us leaders in the industry and we’re very lucky to have him an as associate at Shape, and a part of our team. Jack welcomes Tadashi and his family, pictured above; Tadashi Chikami, his wife, Atsuko and baby Miyu Chikami. "Tadashi, this is your official ‘fun’ welcome to Shape Grand Haven. We look forward to getting to know you better during your time here. And Tadashi, don’t forget to bring in treats on your first day!" BUSINESS UNIT UPDATES FALL 2011 BUSINESS UNIT UPDATES FALL 2011 Jason Meyer General Manager Chrysler/Fiat Business Unit In other news, the International Business Unit continues to grow at a rapid pace, with record international business booked in 2011. We continue to innovate and reinvent our products to meet the ever-expanding global crash and Pedestrian Protection requirements. Our effort to win this business spans the globe. Our associates from Japan, China, Europe and Mexico support us virtually, daily, to exceed our customers' expectations. A sincere thanks to all of you; because, without you, success would not be possible. 7 INLINE. BUSINESS UNIT UPDATES FALL 2011 Jason Bricker Vice President Nissan/Renault Business Unit NISSAN / RENAULT BUSINESS UNIT UPDATE ONLINE. THIS IS WHY WE WORK HARD To support the tremendous growth we've had over the last few years, Shape added a new business unit dedicated to Nissan / Renault in early March 2011. As the new vice president of the Nissan/ Renault Business Unit, I am excited about the business opportunities that have been created through this organizational change. Our global teams have been awarded many projects and currently have launches throughout the world. The European team is currently working on six to seven projects and launches in I am fortunate to have a dedicated group the European region. The U.S. team is of individuals who have been working launching their first cowl and has been extremely hard to make sure the growth of training many of our global associates, this business unit is successful. In doing so, while the Mexico team is in the launch they have given much of their personal time phase of multiple programs along with and energy to make this a successful team. China. Long plane flights, 3:00am conference calls and global travel has required associates to I’d like to thank the entire Nissan/ work some 10-12 hour, or longer, days. But, Renault team at Shape. Your input of you can only go so long before you need a hours to the new product launches, break and a little ‘fun’ to regroup. global sourcing and training has been vital. I know that the trade off is losing We aim to have two team building activities some very special time with your family, each year, one with just the Shape Nissan/ which is why we like to do things to Renault associates and another that make sure you’re still having fun at work involves our families. Because the team has and with your family. Your hard work and been working an immense amount of hours, dedication is paying off. we included our families in our August trip to Michigan’s Adventure. The entire day We like to do things to was devoted to having fun with our spouses and children; eating lunch together, playing make sure you’re still in the water park and riding roller coasters. The reason we were able to take some time off for that fun is because the associates on the team have dedicated much of their time to ensuring the growth of the Nissan/Renault business is thriving. One of our most recent and innovative projects has included working on the active grille shutters for the hybrid electrical vehicles (HEV). In addition, other projects with the Nissan Advanced Group include the head impact cowl strategy and Shape’s next generation of bumper systems. 8 Brian Karabelski, Jason Bricker, Kevin Koetsier, Corey Hoff and Tom Morden (left to right above); traveled to San Diego, Calif. to exhibit at Nissan Design America where they shared Shape's latest advancements and solutions in Pedestrian Protection with Nissan vehicle designers and stylists. LEARN. WATCH. CONNECT. having fun at work and with your family. Your hard work and dedication is paying off. Thank you to Nissan/Renault for being supportive during our time of transition into this new team dynamic. Your continued confidence in Shape allows us to meet your global growth plans. At Michigan's Adventure for team and family fun: Top photo; Sam Campbell (daughter of Rachel Campbell) with Kamryn Dumas (daughter of Karen Dumas). Bottom left; Rachel Campbell with Karen Dumas' daughter, Kennedy Dumas. Bottom right; Lydia Koetsier (daughter of Kevin Koetsier) and Kamryn Dumas. shapepedestrianprotection.com shapecorp.com shaperollforming.com youtube.com/watchshapecorp facebook.com/shapecorp WHAT IS A QR CODE? >> On your smartphone, open your barcode reader app and scan the codes. If you don't have a QR reader yet, download one from your app store by searching 'QR code.' 9 STEPPING INTO THE CONSTRUCTION INDUSTRY CONSTRUCTING RELATIONSHIPS & NEW OPPORTUNITIES FALL 2011 Striving to challenge ourselves and try new things is what makes Shape innovative. So it is no surprise that when Shape was recruited to roll form a part that would be used in the construction industry, the Diversified Products Business Unit took the challenge head on. LAYING THE FOUNDATION Nearly one year ago, SYNTHEON Inc., a building science company that specializes in high-efficiency building envelope systems, approached Shape about roll forming a lightweight, easy-to-install wall system, called the accel-E® Steel Thermal Efficient Panel (S.T.E.P.). accel-E® STEP is a high performance system that shortens construction time, optimizes crew use and improves energy efficiency. The steel frame, combined with insulation, creates the accel-E® wall panel system. Shape was asked to roll form the application using Advanced High Strength Steel (AHSS). Though the construction industry is new to Shape, our capabilities to perform secondary operations in-line and experience with AHSS made us a leading competitor in the business for the product. “Shape came highly recommended for their manufacturing capabilities and first-class customer service,” said Heath Dhayer, supply chain manager, SYNTHEON. For most of 2010, Shape and SYNTHEON worked to develop their relationship in order to ensure the end-result product would be a successful match for both companies. “As the director of construction management and testing, I understand how important it is to forge a custom roll forming alliance with a partner who can adapt to our specific needs,” said Lorenzo Salazar, SYNTHEON. CUSTOMER FRAMING FOR OPTIMIZATION Associates at Shape work very hard to ensure that the plants and equipment are clean and wellmaintained. “5S and robust launch and quality systems are there to protect our customers and are critical to our success” said Jim Rosasco, vice president of Diversified Products at Shape. START OF PRODUCTION: In addition, Shape’s ability to optimize a part to meet a customer’s needs is what makes the company unique. Instead of taking an existing process and simply re-producing the part, Shape optimizes the process to provide a more cost effective product. In this case, the tooling was designed to pierce the hole pattern as a separate operation from roll forming. By reconfiguring the pierce dies, they were upgraded to allow an in-line process, eliminating the need for a separate punching operation. SIZE OF PRODUCT SYNTHEON PRODUCT accel-E® Steel Thermal Efficient Panel (S.T.E.P.). August 2011 MATERIAL High Strength Steel Profiles range from 4 ft. – 44 ft. END USE A building wall system that is strong, lightweight, thermally resistant, highperforming and energy efficient. In August, SYNTHEON, a wholly-owned subsidiary of NOVA Chemicals Inc., visited the 1900 Shape Corp. building to do a trial run on the production of the steel beam. The mill was set up, and SYNTHEON brought in both quality control and evaluation service experts involved to witness Shape associates overseeing a smooth run. PRODUCT CONSTRUCTION There are three different profiles with two material thicknesses. The sizes range from 4 feet to 44 feet. In fact, Shape will be installing an overhead crane to safely and logistically transport this very large product. FUTURE DEVELOPMENT “Working with SYNTHEON is a great opportunity,” said Jim. “We were able to develop a relationship with a new customer in a new market segment. Developing new markets is a journey for us; to remain a leader in our industry, we must think outside the box and looking for creative solutions to meet our customers' needs which will open the doors long term for other untapped markets.” Some of the members of the launch team are pictured above. From left to right: Jamie Ohlendorf, Adrian Winesett, Scott Vedders, Jarra Hilliker, Todd Dumbrell, Andy Rosenberg, Travis Vaibar, Marty Blanchard, Amy Kolkema, Chuck DeWitte, Jeff Sova, Paul Tiefenthal, Jeremy Wollen, Nick Ruiter, Mike Shirrell, Pat Hood, Nick Schuitema, Tom Vanderwall, Gordon Chapman, Paul Luna, Joe Arens. 10 11 “We want associates at Shape to create meaningful relationships with each other,” said Doug Peterson, vice president, human resources. “As we continue to expand it's imperative that we grow together as a global family.” Make GREAT Parts. Be Fair. THE SHAPE BUNCH FALL 2011 HAVE FUN! Doug Peterson on Shape Culture Tom DeVoursney Marching Orders The on Career Growth John Achterhoff on Giving Back Bunch Rewind back to 1969….the first man set foot on the moon, Richard Nixon became president and “The Brady Bunch” aired on television for the first time... Life was changing rapidly in 1969 and traditional values were beginning to fade, but a television show, “The Brady Bunch,” starring a blended family of eight, remained focused on family roots and traditions, just as it remains a focus at Shape. Embracing a culture that takes its associates into consideration is rare. How often do you see the president in another company? Probably not as much as you see Tom DeVoursney making appearances at Casey Turner – John Achterhoff, manufacturing engineer SHAPE Founded in 1974 as a privately owned family company, Shape believed in values such as being fair and having fun in the workplace. Throughout the years, these traditional values have remained the same, proving that they do have their place in a progressive, corporate culture. We like to think of ourselves as one big and growing family (like the Brady Bunch!) because that’s how we started as a company. Since inception, our leaders have worked hard to remain true to our original core principles. 12 “I just enjoy helping people. I like to see people smile when a job is done and done well. Or, seeing the relief on their face when something is taken off of their shoulders. Too often, you hear people say, ‘I am too busy,’ but if we all pitch in a little, it goes a long way.” Shape. He is at every quarterly meeting cheering on associates, commending them on a job well done and updating associates on where Shape stands financially. He even leads the company’s tradition of the Shape cheer. But at Shape, our culture is more than the values and leadership. It’s the associates that have made Shape what it is today. Each associate’s commitment to go above and beyond, willingness to try new things, and continuously building relationships has contributed to Shape’s unique culture over the years. Pictured here are eight individuals that represent unique parts of our culture, each of them contributing something different to make the “Shape Corp. Bunch.” “Since 2004, Shape has helped me develop my role and encourages me to work toward my ideal job, which has always been in manufacturing. I’ve done everything from being a manufacturing engineer to packaging because Shape has given me the opportunity to take on more responsibility. I have never felt like a number here and have felt my contributions were valued and appreciated from day one. I’ve tried to cascade this same appreciation to the team in each of my roles. I have really enjoyed watching the company and the teams grow and develop year after year.” — Casey Turner, Plant Manager Jonathan Brian Malkowski Padilla on Shape on Shape Innovations Mexico “Shape is concerned about the health of all associates. The company encourages exercise and this is a good way to motivate employees. The communication is face-to-face, with all levels of the company. The support from Grand Haven is very good and clear. I love working at Shape and I enjoy my job!” — Jonathan Padilla, Welding Engineer Kenya Michael Velasquez Thompson on Wellness Program on Family Events Brian Malkowski on Shape Innovations “When I was hired at Shape, I started working out at the Fitness Factory. Since then, I have lost 25 pounds! People should go and take advantage of what the Fitness Factory has to offer. It’s free and good to be healthy and fit. I do cardio and some strength training like pull ups, push ups and squats. There are people there to talk to you about your fitness goals and everyone is so helpful.” — Kenya Velasquez, E-Coat Hanger Michael Thompson on Family Events “Shape’s desire to stay ahead in the automotive industry and a leader in design and manufacturing is what makes us an innovative company. I think one of our most innovative technologies is our sweeping process because we’re able to do things no one else can do—specifically, our ability to create highly engineered cross sections that utilize Advanced High Strength Steel.” “I’ve gone to Shape’s annual Easter Breakfast for 20 years now, as of 2012. And before that I went as a temp! I think it’s a great chance to meet other employees in different buildings and sister companies, and a good way to meet other families. You can enjoy yourself and eat a good meal. I used to bring my nieces and nephews, and now that they're “too cool” for it, I bring grandkids and great-grandkids.” — Brian Malkowski, Product Development Engineer — Michael Thompson, E-Coat Hanger 13 PEDESTRIAN PROTECTION FALL 2011 Three actions we’ve all heard since childhood. Three actions taught to keep us safe while crossing or walking along a busy street. At a time when pedestrian to motor vehicle accidents are a growing problem, Shape Corp. is taking the hand of pedestrians everywhere by providing parts that make vehicles more pedestrian friendly. With new technology gadgets, increases in traffic volumes and more pedestrians on the streets, drivers and pedestrians are becoming more distracted and prevalent on the roads they share. These are only a few of the contributing factors to the increasing global problem of pedestrian to motor vehicle accidents. government agencies and organizations have implemented safety regulations and requirements specific to Pedestrian Protection. Europe and Japan have taken the lead on implementing such regulations by incorporating pedestrian safety into The odds of dying in a pedestrian to motor vehicle accident are now EEVC WG17 and EuroNCAP. From there the importance of one in 649, a greater chance of dying than in a motorcycle accident. these issues have spread across the world, which resulted in Around the world more than 400,000 pedestrians are killed each creation of the Global Technical Regulation (GTR) No. 9 by year. In Michigan alone, 118 pedestrians were killed in 2009. the United Nations. Currently, most countries are signatories Numbers, such as these, have caught the attention of automotive of GTR. Automakers have begun designing vehicles to safety teams, engineers and manufacturers worldwide. meet GTR and Shape is at the forefront of developing countermeasures that will make the vehicles GTR compliant. Drivers and pedestrians both need to be cautious of their surroundings and follow the rules of the road; however, humans *Statistics provided by the National Safety Council, are capable of error and accidents do happen. To reduce the Insurance Institute for Highway Safety and the Governors impact and severity of pedestrian to motor vehicle accidents, Highway Safety Association. HEAD 24% 20% 58% CHEST ABDOMEN RULES OF THE ROAD Tips to Keep You Safe In and Out of the Car *Statistics provided by Michigan Office of Highway & Safety As a Pedestrian As a Driver • No pedestrians are allowed on limited access highways. • Driveways and parking areas are hazardous. Pull out slowly. • Pedestrian crossing signals must be obeyed. • In public garages, drive-through businesses and commercial lots, watch out for those on foot or two wheels. • Pedestrians may not walk in the roadway if sidewalks are present. If there are no sidewalks, pedestrians must walk on the left side. • Wait for drivers to stop and make eye contact before crossing. • Look in each direction, especially when crossing sidewalks and marked paths. • Sidewalks are safer than roads, but watch for driveway traffic. • Before turning right on red lights, drivers must stop fully. Make sure no pedestrian, jogger, bicyclist or wheelchair user is crossing or waiting to cross. They have the right of way. • Bicyclists should ride with the flow of traffic, ideally in marked lanes. • Motorists turning left on green lights must yield to anyone crossing. • Cross at a corner or marked walkway, following traffic signals. • Look left-right-left before crossing any street. 27% This graphic shows where most serious and fatal injuries occur when a vehicle strikes a person. 44% LEG As you'll see, the head and legs are where the majority of injuries are sustained. Therefore, Shape has concentrated its product development efforts on these key impact areas. % Serious Injuries % Fatal Injuries 14 15 At Shape, we have countermeasures that meet the requirements for vehicle protection and Pedestrian Protection. Global bumper regulations require stiff and stable bumpers, but Pedestrian Protection requirements seemingly require a soft bumper system, thereby posing quite a challenge for manufacturers. Our advanced product development team has overcome those PEDESTRIAN PROTECTION Countermeasures by Shape-NetShape LOWER BUMPER STIFFENERS LEG ENERGY ABSORBERS The lower bumper stiffener helps reduce knee bending /injury and knee shear. • Ability to include RCAR damageability and high speed countermeasures Bumper to leg energy absorbers help reduce high load, bending moments and knee acceleration/injury during an impact. • Enhanced flexibility with a variety of solutions • Higher energy and crush efficiency over EPP foam energy absorbers • Low mass and cost • Parts nest together • Multifunctional energy absorbers that work for Pedestrian Protection, FMVSS 581 Low Speed Impact and IIHS/ RCAR Bumper Barrier Impacts HEAD IMPACT ENERGY ABSORBERS Components designed to absorb energy in the event of a head to hood impact. Intra Hood EA • Low mass • Provides local impact energy management • High temperature options Plenum / Inner Cowl • Lightweight, high strength material • Energy absorption Deployables • Low mass • Reduces event injury – less potential for out-of-position injury • Fast deployment m .co te ro tr es d Pe P ian e p ha Cowl S w. ww Deployable Hood Lifter HEAD IMPACT TEST Adult and Child Head Tests LOCATION | Grand Haven, MI SPEED | 35-40km/h (25mph) REQUIREMENTS | GTR, EuroNCAP, JNCAP, EEVC SHARING EXPERTISE Upper Leg Energy Absorber Pedestrian Protection is the first consideration when automakers begin vehicle styling. Shape works closely with OEM vehicle development engineering and styling departments to help navigate through design challenges using innovative, flexible Pedestrian Protection compliant technologies. Lower Leg Energy Absorber Steel Bumper Stiffener Plenum Intra Hood Absorber Lower Bumper Stiffener Belly Pan 16 LEG IMPACT TEST Upper and Lower Leg Tests LOCATION | Grand Haven, MI SPEED | 40km/h (25mph) REQUIREMENTS | GTR, EuroNCAP, EEVC WATCH THE VIDEO NOW! www.ShapePedestrianProtection.com Follow this link or snap the QR code to go directly to a YouTube video that stresses the real life importance of this issue followed by a montage of Pedestrian impact tests recorded at Shape's Technical Center. As regulations continue to be implemented around the world, we want our customers, local and global, to have the expertise they need. To support them, we have gone on-site to their facilities to inform and allow anyone whose contribution to vehicle development is affected, to ask questions on the impact of the new regulations and how to meet those requirements. In addition, we have been exhibiting and presenting at global vehicle safety trade events to share our expertise. PEDESTRIAN IMPACT TESTING Cowl / Leaf Screens / Air Inlet Panels • Lightweight • Energy absorption • Serves multiple functions for vehicles on cti When performing the lower leg impact tests, the testing component that simulates a human leg is wrapped in a blue Confor foam material to represent the leg exterior. To make a connection between real life scenarios and the testing procedures, we are using the blue legform as a representation of Shape’s dedication to Pedestrian Protection. When making components for the vehicles we drive, our families drive, our community members, our customers and their families drive, we can’t help but want to make those vehicles safe for not only the vehicle occupants, but also for those walking across or along the road. With the increased need and importance of Pedestrian Protection, we have taken the challenges by designing and manufacturing vehicle components with lower load levels. We have increased the energy absorption capacity and the efficiency of the absorption to manage both requirements. Vehicle safety is a priority when designing and producing our vehicle components. In any event of a crash we want to protect you the best we can. Be a part of our initiative, as both a driver and a pedestrian. Remember to STOP, LOOK and LISTEN in order to protect yourself and those around you. WHAT IS THIS BLUE LEG? existing and pending global regulations, and implemented them into our components’ design and testing performance. At Shape, we test our vehicle components to validate that existing and proposed countermeasures will perform for maximum Pedestrian Protection in the event of an impact. To fulfill Pedestrian Protection requirements, series of tests must be completed on components in regards to their vehicle zones (i.e. head impact, bonnet leading edge and leg impact). Shape’s Technical Center is capable of performing all global Pedestrian Protection tests on a vehicle from head impact on the windshield to leg impact on the bumper. The test results attained from Shape’s test lab correlate precisely with the EuroNCAP test results demonstrating Shape’s high level of expertise. PEDESTRIAN PROTECTION FALL 2011 HOW SHAPE PROTECTS PEDESTRIANS 17 START Have you ever seen a window blind used in a manufacturing facility for something other than shading? Or a dust pan used for something other than picking up dust and dirt? At Shape you will. That’s right. Shape’s been playing with blinds, dustpans and wood – but for good reason. Shape has reduced injuries, made better use of facility square footage, and increased productivity. The Shape Production System has been the vehicle to improve current manufacturing systems and processes. Good things were happening, but something was missing… How do we get ahead of the curve? Why wait until a product has launched to use the tools of the Shape Production System? The answer was in the development of a pre-launch SPS Workshop for new product launches. What do dustpans and blinds have to do with this? They are really just a small part of process used at Shape to identify waste within products and processes, before the launch of a new program. END OF GAME After the part design and manufacturing logistics are understood and an acceptable product “mock up” has been created, the team follows the pre-launch SPS Workshop process for reducing variation and eliminating waste. First, the team develops a current state process flow map of the production process. Each step is documented and timed. The process flow map is also accompanied by a spaghetti diagram of the operator and material travel path of the process. Next, an evaluation of manufacturing and ergonomic wastes takes place. Sources of variation and waste are identified and improvements are made by the team. PLAYING WITH A PURPOSE Say goodbye to the old days of catching problems with products after the manufacturing process has already started. Shape associates found a way to stay ahead of the curve in lean manufacturing by identifying issues prior to production. AGS SIMULATION The product above was created in a May 2011 pre-launch workshop to simulate the active grille shutter systems. The window blinds represent shutters, or louvers, and the dustpan simulates a cover that would snap into place to cover the motor and act as a retention piece to hold the upper louvers. HOW TO PLAY First, backgrounds and assumptions of the product and process are gathered allowing the team to accurately assess the materials and processes that will be used to make the end product. CAD drawings and surrogate processes are used to determine what the process may eventually look and feel like. Once a general idea of the process has been established, the team analyzes product volumes, quality requirements and customer locations to determine manufacturing logistics. How many shifts of production per day? How many days of production per week? All of this data is assembled and the team gathers for the workshop. Because the workshops are preproduction, there are no physical parts to determine how to reduce variation and eliminate waste in the process, so Shape associates compromise. The team gathers materials that can be assembled into a realistic “mock up” of the finished product. Weight, size and form all play a role in the determination of the pre-product material. For example, when evaluating the active grille shutter process, a dust pan and window blinds were used to simulate a grille. For the roof rack, the manufacturing maintenance team used wood to carve out the correct size and shape of a simulated aluminum tube and injection molded plastic. The goal is to give the team physical pieces to simulate their work environment. This activity provides insight to the process that paper and pencil cannot. What does it feel like to move a component that is 96” long? How close should a bin of fasteners be for assembly? The simulation provides answers that lead to better processes. 18 THE PLAYERS The workshops consist of a team of Shape associates including the program manager for the product, the manufacturing associates who will be producing the project, as well as hi-low drivers, production supervisors and engineers. Associates who are willing to give open and honest feedback work well in these teams. A process in the design phase needs someone who is not afraid to say, “I think we should try it this way,” or “I’m willing to try something a little different to see if we get the right result.” In Shape’s culture, associates are encouraged to take risks if the reward in the end will better the company and associate. GAME CHANGER “I’d say this is a new chapter within our lean manufacturing journey,” said Scott Bacon, lean manufacturing engineer. “It began in early 2010 as an evolutionary step of the Shape Production System. In the past, we focused primarily on optimizing our current production processes. We are working to reduce variation and eliminate waste even before the product and process is launched. The real advantage is the talent and insight of our teams. Seasoned operators are a game changer in designing a stable manufacturing process. They can tell you what will and will not work,” said Bacon. LOCATION New hire training WHAT Process simulation representing a roll form line from start of production to completion to shipping. PURPOSE To teach new Shape associates the lean manufacturing process WHAT PRODUCTS HAVE BEEN IMPLEMENTED WITH THIS PROCESS? • Cowl Assemblies • Active Grille Shutter Assemblies • Roof Rack Assemblies • Steel Bumper Assemblies • Aluminum Bumper Assemblies The result is a future state process flow map. The team places high value on designing work to see problems so there is a clear signal on when to ‘PULL THE CORD’ and ask for help during production. Finally, the team drafts an action plan of what needs to occur to implement all of the ideas simulated in the pre-launch SPS Workshop. The plan is presented to the leadership team to ensure that roadblocks are removed and resources are available. Shape associates are actually doing much more than sweeping up dust and shading their offices from the sun with dust pans and blinds. They’re taking a very unique approach to lean manufacturing with everyday household products, and solving manufacturing problems before they even hit the production floor. REGIONAL UPDATE SUMMER 2011 PLAYING WITH REASON: SPS WORKSHOPS FALL 2011 When Shape began its lean manufacturing journey in 2008, its ultimate goal was to streamline its current manufacturing processes. Workshops were conducted and actions implemented to reduce variation and eliminate waste in the process while improving efficiency and product quality. Value Stream Mapping was embraced to guide where improvement activities should be focused. Through dedication and teamwork, WHY DID SHAPE START THESE WORKSHOPS? “We started implementing the workshops for several reasons,” said Bacon. “We are always working to improve product quality and process design and we want machines that run well and are ergonomically good for the operator,” said Bacon. WHAT ARE THE BENEFITS OF SPS WORKSHOPS? • Improving product quality • Optimizing operator ergonomics • Refining machine design • Establishing a better co-relationship between engineering and manufacturing teams FUTURE PLAY “Identifying waste early is key to optimizing Shape’s processes,” said Bill Andrews, vice president, global manufacturing. “Getting associates involved up front helps ensure we get the least wasteful process possible. The workshops will continue to be an integral part of our launch process as we move forward.” 19 LENDING A HAND LOCALLY FALL 2011 LENDING A HAND LOCALLY Shape associates have been busy this summer volunteering their time and energy to people and places in need of a hand. Various teams and individuals have taken time out of their busy schedules to help with everything from Coast Guard Festival to transporting mounds of books and blazing trails. Robinson Township Park Trail Women’s Library Books Volunteers: GM Business Unit and Shape Young Professionals Group Volunteers: Building and Corporate Maintenance Team Volunteers: Shape-NetShape China Robinson Township needed a trail so the GM Business Unit and Shape Young Professionals came together to make it happen. John Achterhoff brought his Bobcat to rip up tree stumps, while everyone else took shovels, hatchets and any other tools to tear down the woods, grass and shrubs to build a walking trail. With dedicated Shape associates, the entire trail project was almost finished in its entirety by 11:00am – and was only started at 8:00am that day! The associates enjoyed lunch together and then finished up the rest of the trail by 3:00pm. Shape’s Building and Corporate Maintenance department teamed up with the Grand Haven Football team to move boxes and boxes of books from Rosy Mound Elementary to the Arts and Crafts Fair in Grand Haven during the Coast Guard Festival. At 8:00am, in less than 15 minutes, the books were moved from the library and loaded on the Shape trucks. Each year, the Grand Haven Women’s Club sells the books and the money earned is put toward scholarships. They made more than $4,000! Shape-NetShape China organized a community responsibility activity at a local Kunshan Rest Home. Mike Smith’s wife, Mary, Dave DeYoung’s wife, Dennese, and Penny Watson prepared some homemade soft breads and cookies to give to the elderly members of the home. They chatted and had fun with the people there. One 94-year-old lady also sang a local song to them! Everybody enjoyed the activity and the principal of Rest Home also expressed his appreciation for the team's voluntary service and was deeply impressed by Shape’s voluntary activity. Associates who participated included: Amy King, John Achterhoff, Chuck Michele, Scott Glasgow, Dee Parsons, Charlie Peterson, Kevin Bock, Rosanna Scott, Roci Lee, Rob Weykamp, Dennis Rupar, Jeff Szost, Mike Hall, Barry Dues, Mike Marzolf, Dave Powell and Mike Walcott. Yard Crashers Shape Style Volunteers: Stampings Business Unit “You know you work for a great place when co-workers are willing to do THIS for you.” This is a statement from a very grateful Shape Stampings associate who has been out on medical leave since March. Shape Stampings associates “crashed” his family’s yard for a two-day makeover. Due to his back injury, the associate has been unable to do his annual summer yard work, so Stampings associates Mike Hawkins, Gordy Fowler, Cameron Powles, Sue Killilea, Chuck Michele and John Achterhoff, pitched in to lay new mulch in his landscaping, weeded the garden and rebuilt his entire shed. 20 Kid’s Day at Coast Guard Volunteers: Purchasing and Logistics Team The materials team took the time to volunteer on August 2 at the annual Coast Guard Kid’s Day at Mulligan’s Hollow. Kid’s Day is a great opportunity for children in the Grand Haven and surrounding areas to play games, have fun and participate in activities. Shape employees helped run the carnival games and the water table, keeping everyone who came out hydrated on the hot, steamy day! Kunshan Retirement Home Associates who participated included: Mike Smith, Dave DeYoung, Penny Watson, Cindy Shen, Rocky Hu, Vicky Guan, Christina Ma, Yolanda Wang, Tina Wang, Changbo Yao Associates who participated included: Jeff Hoekstra, Pat O’Brien, Dave Birr, Todd Dumbrell, Rick Thompson, Travis Vaibar, Joe Rotonda, Bryan Swiftney, Jim Post, Jeff Maus, Lisa Major, Matt DeGram, Mike Pavacik, and Kevin Wickering. Front: Andy Malnor and Kelli Schroeder. Missing from the picture: Chuck Michele 21 2 AFTER HOURS What do you do after work? Shape Corp. associates share hobbies that occupy their time after they punch the clock. 5 for Sport 3) Sailing Featuring: Peter Sturrus John Achterhoff is a force to be reckoned with at work, where he is a manufacturing engineer at Shape Stampings. At home he stays busy being on call as a part-time fire-fighter at White Lake Fire Authority, a photographer, an ATV enthusiast, a member of theh Sea Hunt Dive Club and the Muskegon County Sheriff’s Department Dive Team. John and his wife of five years, Cindy, have gone scuba diving everywhere from the Caribbean to a Michigan pond to retrieve a farmer’s truck. They have also dove below the ice to assist drowning victims, and have explored Lake Michigan shipwrecks. Sleep is overrated to this Shape associate who would rather be helping people, doing something outside, or preferably both! Shape-NetShape China’s soccer team, made up of associates from manufacturing, financing, purchasing, and quality had an exciting competition with SGM Exterior Engineering, the company responsible for all GM bumper designs in China. The team played well, had a great time, and graciously allowed their customers to win by a single goal. Both teams left happy and have already scheduled a re-match. In the meantime, S-NS China’s soccer team continues to work on strategy and tactics at their practices… they won’t be letting their customers save face next time! Growing up, Peter Sturrus’ family had power-boats, so it wasn't until five years ago that he was introduced to it by his fiancée, Lindsey. Since then he has come to love it. On Wednesday evenings you can find them, along with Lindsey's father and a few friends, racing their 26 foot, Holland, Michiganmade, S27.9 sailboat on Muskegon Lake. They raced weekly in the summer series and currently in the more intense fall series when winds pick up. Last year they took second in the Anchorage Cup. “Sailing is a lot of fun,” said Peter. “You need to be in tune with your surroundings and really trust your team to be on top of things to be successful.” In the future, they hope to someday take the boat all the way down to the Caribbean and compete in the NOOD Regatta, a nine city sailboat racing circuit. Steps for Big Strides 4) Little Featuring: Sarah Heins Walking 60 miles in three days, with the vision to accomplish one goal—to end breast cancer—proved to be more of a life changing experience than Sarah could have ever imagined. The strength, drive and positive attitudes among those she shared the adventure with gave her motivation and appreciation for being a first time walker. Until the 3 Day for a Cure, Sarah had never heard so many extraordinary stories of courage, optimism and triumph in one weekend, or a lifetime for that matter. All of the stories and efforts combined of the walkers, volunteers, crew members and survivors contributed more than $4.1 million to the fight against breast cancer. Sarah is proud to tell you that those dollars ARE making a huge dent on the disease locally and globally. These efforts and donations have aided to the 98 percent success rate of fighting breast cancer when caught in the early stages. 4 3 Décor at Home 5) Haunting Featuring: Don Bogue Don Bogue, building maintenance at the 1900 facility, prides himself on having the spookiest house in the neighborhood for Halloween. For the past 10 years Don has been collecting decorations, many of which he built himself, in order to give neighborhood trick-or-treaters a truly haunting Halloween experience. Come Christmas time, Don will completely redecorate with more than 50,000 Christmas lights over his two acre yard! 8) Hitting the Open Road Featuring: Steve Hackney Steve Hackney, a maintenance leader at 172, keeps busy in his free time volunteering as Shape team captain for the American Cancer Society’s Relay for Life. A cancer survivor himself, Steve was diagnosed in 2008, but has now been cancer free for almost three years, and likes to give back whenever possible. When he is not working or volunteering, Steve loves to go on motorcycle runs with his son James. His favorite trip was a recent three day run when the two of them rode up to the Mackinac Bridge and back. Sarah is extremely grateful for all of the support from her family, friends and coworkers who helped her be a part of an amazing experience and who contributed to the fight against breast cancer. Walk on! 7) Unplugging Featuring: Danielle & Jeremy Schmidt 6 22 Team Bonding 2) Featuring: S-NS China, Michael Wang 7 Jeremy Schmidt, shipping supervisor at 1835, along with his wife Danielle, administrative assistant at 172, took a week to get away from it all with their two children. Avid campers, they take weekend trips as often as possible and plan one big trip every summer. This year’s trip took them on an adventure to Maple Bay State Forest in the Petoskey area and Tahquamenon Falls in the Upper Peninsula. During their trip they went fishing, swimming, exploring, and were terrorized by an organized band of raccoons with a taste for donuts! The best part about their trips is getting a chance to unplug from society and enjoying family time outdoors. Sound of Music 6) The Featuring: Thomas VanderWall AFTER HOURS FALL 2011 1 Scuba Diving Firefighter 1) Featuring: John Achterhoff Thomas VanderWall, a fabricator at 1900, spends most of his nights running live sound or DJing at different venues throughout West Michigan. Wedding receptions are his favorite events to DJ, but clubs are a close second. He loves playing various types of music genres for people and having the opportunity to work on stage with different bands. So far, his music library has 50,000 titles (all legal!), because he loves staying up-to-date on the newest music and technology. He has been sharing his talent as a DJ for 13 years now and it just keeps getting better! Relaxation and Racing 9) Rest, Featuring: John Dykstra When not at work, John Dykstra, a tooling engineer at Shape’s 172nd facility gets a rush from taking a spin in a 550 horsepower car around the Berlin Raceway in Marne, Mich. John’s first taste was in the fall of 2006 with Shape’s digital tool and die group, and ever since, he has been going as often as possible. John takes his sons to see races when he has the chance and encourages everyone to try racing because ‘it is an adrenaline rush that doesn’t get any less fun!’ Energizer Becky 10) Featuring: Rebecca Moll The Fitness Factory’s Rebecca Moll is all about staying active and energized, both at work and after hours. When she is not teaching Spin, Spin & Pump, Zumba, Pilates or Yoga she loves to be outside enjoying the summer weather with her two sons Jess, 10, and Jake, 7. Their favorite activities include going to the beach, camping around West Michigan, and hiking and biking trails in the Muskegon and Grand Haven area. 23 1900 Hayes St. Grand Haven, MI 49417 PRSRT STD US Postage Paid Permit No. 1 Grand Rapids, MI CELEBRATING SHAPE'S 10TH GM SUPPLIER OF THE YEAR AWARD Shape and GM have a little fun on the football field to celebrate Shape's 10th Supplier of the Year Award.