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
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New Website on
ROLL FORMING
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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
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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
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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
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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.
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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.
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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.
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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.
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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.
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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
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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.
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“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.
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“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.