Our Lean Journey A CONTINUING JOURNEY TO EXCELLENCE

Our Lean Journey A CONTINUING JOURNEY TO EXCELLENCE © 2013 DST Systems, Inc. All rights reserved. © 2013 DST Systems,

Agenda 2 Our original Goals How our Journey Began What we looked like before The Idea What we look like now Tools we introduced Our search for waste What are we doing going forward Results © 2013 DST Systems, Inc. All rights reserved.

Our Original Goals 3 To improve quality To improve productivity To improve profit To attract more custom © 2013 DST Systems, Inc. All rights reserved.

How Our Journey Began 4 Looked at our factory and knew things had to change VIP help us with our first 5 C exercise Had to rejig the factory layout Planning, Planning and More Planning © 2013 DST Systems, Inc. All rights reserved.

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The Way We Were 9 © 2013 DST Systems, Inc. All rights reserved.

The Idea 10 © 2013 DST Systems, Inc. All rights reserved.

The Way We Are 11 © 2013 DST Systems, Inc. All rights reserved.

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Tools We Introduced 14 5 c OEE TPM Product Flow © 2013 DST Systems, Inc. All rights reserved.

5 c 15 Began with training in all areas Introduced 5 C Walks Monthly 5 C Audit All very successful © 2013 DST Systems, Inc. All rights reserved.

5 C Audits 16 © 2013 DST Systems, Inc. All rights reserved.

OEE 17 Next we had to look at how we perform Again VIP helped us with our first workshops Been a slow process Time sheets Soon to be automated Using the data have reduced portering © 2013 DST Systems, Inc. All rights reserved.

18 © 2013 DST Systems, Inc. All rights reserved.

TPM 19 Each machine on the shop floor has a TPM book to record the daily, weekly, monthly tasks On a monthly basis we record how effectively the operators have been in Performing the TPM Tasks Through OEE we track maintenance downtime and determine areas of concern and proposed actions © 2013 DST Systems, Inc. All rights reserved.

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Used Value Stream Mapping 21 Mini Warehouse (Job Assembly) Bench Planning Postage Projects Remake Area © 2013 DST Systems, Inc. All rights reserved.

22 © 2013 DST Systems, Inc. All rights reserved.

Our search for waste 23 Put up the following poster Got reaction, not necessarily what we wanted Bill and I Had some explaining to do Our wanted poster is still up as Tim is a very illusive character © 2013 DST Systems, Inc. All rights reserved.

24 © 2013 DST Systems, Inc. All rights reserved.

Results 25 More clients Increase in volume-more packs mailed out than ever Profitable Increased opportunities for investment A site that we can be proud of © 2013 DST Systems, Inc. All rights reserved.

Going forward 26 Implementing Net Consent Introducing two hour work shops as a refresher Continue refining our factory layout More Value Stream Mapping Exercises The recording of OEE and TPM data will be automated © 2013 DST Systems, Inc. All rights reserved.

Closing Thought 27 What we have found with all of the Lean tools that have been implemented in Dagenham is that none of them will get off the ground without their ownership being firmly in the hands of the recipient. BUY IN is the key ingredient to any successful implementation © 2013 DST Systems, Inc. All rights reserved.