Quick start [Vol. 9, no. 1 (Spring 2007)]

Georgia Department of Technical and Adult Education

SPRING 2007 VOLUME 9, NUMBER 1

Training that Sticks

Top: An Oracal employee visually inspects the company's self-adhesive vinyl film. Center: Christian Hersacher, Oracal director of manufacturing engineering. Bottom: Rolls of Oracal film are shipped from the Bryan County facility.

Adhesive-film maker Oracal speaks Southern with a German accent
Christian Hersacher, director of manufacturing engineering at Oracal in Bryan County, remembers when he first learned about Quick Start. Oracal was looking for a site in the United States, and they came to see what Georgia had to offer.
"When I first entered the Quick Start office in Atlanta, it was so different from what I experienced in other states," Hersacher says. "All the technology there and the professionalism of the entire organization were really amazing."
Oracal, the U.S. arm of Orafol Europe, a 200-year-old international company based in Oranienburg, Germany, was impressed enough by the efforts of Bryan County's economic development team, the Georgia Department of Economic Development, and the training services available through Quick Start and Savannah Technical College, that they eagerly picked the rural site and started building their new facility in 2005.
Continued on page 10

QUICK START IS GEORGIA'S PREMIER SOURCE FOR ECONOMIC DEVELOPMENT TRAINING

Quick Notes

"Quick Start is proud to be among the first of Georgia's economic development teams to work with international companies coming to the state."

About this issue: Global Georgia

Governor Sonny Perdue has recently put a renewed emphasis on a "Global Georgia." This initiative will help increase the awareness of Georgia in coun-

Belgium

tries and markets around the world, helping Georgia's businesses expand into

overseas markets, as well as helping Georgia's communities attract new invest-

United Kingdom

ment from international companies. We at Quick Start are excited to be a part of

the "Global Georgia" initiative because working with international companies is

one of our specialties.

USA

In this issue of Quick Start's newsletter, we highlight projects from five differ-

ent countries. Our cover story is on Oracal, a German company located in Bryan

County, which has built one of the most sophisticated, "green" manufacturing facilities in the state. In addition, some of our latest projects mentioned in this

Germany

issue have been with companies from England, Italy, Japan and Belgium.

Quick Start is proud to be among the first of Georgia's economic develop-

ment teams to work with international companies coming to the state. Helping

Japan

facilitate cross-cultural communications and train Georgia's workforce in unique

production processes are just two of the critical skills we're able to bring to the

table as we all work together to

grow our "Global Georgia."

Italy
Angela Della Costanza Turner,

Honorary Italian Consul of

Atlanta, speaks about the

opportunities Georgia offers

international businesses at

the grand opening of Aquafil

USA in Cartersville.

Jackie Rohosky
Assistant Commissioner Economic Development Programs jrohosky@georgiaquickstart.org

Table of Contents

3 Events Around the State
16

18 Make the Call ProCore Solutions meets chal-

12 A Fine Polish Abrasives-maker Glit/Microtron

lenges with Quick Start training

goes lean, wins big

20 Quick Start

Project Announcements

14 Shifting into Overdrive

Honda Precision Parts of Georgia

14

revs up with Quick Start

16 Progress Reported The 13th Annual Manufacturer of the Year Awards

Spring 2007 Volume 9, Number 1 Published by Georgia Quick Start www.georgiaquickstart.org Quick Start is a registered service mark of the Georgia Department of Technical and Adult Education Ron Jackson, Commissioner. Please address comments and questions to: Rodger Brown, Director of Communications rbrown@georgiaquickstart.org GA Quick Start 75 Fifth St. NW, Suite 400, Atlanta, GA 30308
2

Events

From left: Jan Melcher, Quick Start director of eastern operations; Gordon Cooper, JCB general manager manufacturing; and Dr. C.B. "Bix" Rathburn, Savannah Technical College president.

Reporting for Heavy Duty

In 2000, British equipment manufacturer JCB built its first "Made in the USA" backhoe at its new North American headquarters in Savannah. Quick Start helped train the company's first all-American workforce then, and again in 2004, when JCB added the Robot skid steer loader to the line of products manufactured there. Savannah Technical College has provided additional educational services.
Now, the company is building on the popularity of its products "Made in the USA" with some "Made for the USA." In a recent expansion expected to create about 250 jobs, JCB is adding two new products to its Savannah line. A High Mobility Engineer Excavator (HMEE) and Rough Terrain Forklift (RTFL) will be produced specifically for the U.S. military. And once again, Quick Start and Savannah Tech are helping the company meet the demands of success. "As JCB expands to meet increased demand for its construction equipment, in addition to adding these two new products, Quick Start is proud to help the company build and train its growing workforce," said Jan Melcher, Quick Start director of eastern operations.

CEDT Panel Meets (Clockwise, from top)
John Spoltman, Honda Precision Parts of Georgia vice president, participates in an economic development panel for the 12th class of the DTAE's Certified Economic Developer Trainer program (CEDT); Spoltman talks about his company's relationship with Quick Start at the event, part of an 18-month certification process for DTAE personnel; Charlie Gatlin, Georgia Department of Economic Development chief of staff, gives an overview of Georgia's global commerce at the event.

Quick Start News g Spring 2007 3

Events
Representatives from the city of Rincon, Effingham County and state government gather to officially open Flint River Services' new warehouse and distribution center.

Have an Ice Day
New employees are coming into the cold at Flint River Services' newest facility, a 250,000-square-foot warehouse and distribution center in Rincon, Ga., where they'll provide cold storage, blast freezing, distribution and logistical services for food processors and manufacturers across the country.
Now the second-largest employer in Effingham County, Flint River Services is working with Quick Start to build and train an initial team of 100 employees. Savannah Technical College will provide ongoing educational services.
"We had a great experience working with Quick Start when we opened our Unadilla, Ga., distribution center, and it was a real bonus to find we could do it again," said Stuart Geriner, the company's controller. "Thanks to Quick Start, implementing employee training at this new plant has been smooth and seamless."

Grateful Tread

Some Quick Start team members had lunch with representatives from Toyo Tires recently, as the company hosted an event recognizing Quick Start's contribution to the successful launch of Toyo's first North American manufacturing facility.
"Our president and CEO, Mr. Shozo Kibata, joins me today in extending our warm appreciation to the Quick Start team, whose excellent training programs have saved us at least six months of start-up time, and which have contributed to this facility achieving profitability within a record 18 months of opening," said Toyo Senior Vice President Jim Hawk. "What Quick Start has done for us is phenomenal."
Toyo Tire and Rubber Company opened the facility in June 2004, after selecting Georgia over sites

from China to Alabama. Today, the company employs approximately 380 people and expects to double that number. Quick Start will continue to partner with Toyo to ensure that its successful training programs continue.
"All of us at Quick Start feel like part of the great Toyo team," said Jackie Rohosky, DTAE assistant commissioner of economic development programs. "We are especially proud of your rapid success here in Georgia."

4

Teaming Up -- Terminix, the largest termite
and pest control company in the world, recently entered into an agreement with Quick Start and Gwinnett Technical College to provide training in core business and computer skills and in leadership and human resources development for 90 employees of the company's new Norcross facility. Pictured signing the training plan are, from left: Jackie Rohosky, DTAE assistant commissioner for economic development programs; Kevin F. Bock, Terminix director of inside sales; and Sharon Rigsby, Gwinnett Tech president.
Above: Staff from Quick Start and Toyo Tires outside Grand Oaks in Cartersville. At left: Jim Hawk, Toyo senior vice president, accepts a framed copy of a Quick Start News story about his company.

From left: Mike Moye, Lanier Technical College president; Ron Baysden, Impulse Mfg. president; Jeff Lynn, Quick Start director of northern operations; Jackie Rohosky, DTAE assistant commissioner of economic development programs; Russell Vandiver, Lanier Tech VP of economic development; and Bobby Densmore, Impulse Mfg. director of operations, tour the metal fabrication company's facility in Dawsonville, Ga.
Acting on Impulse
The baggage-handling system in the Seattle airport, the croquet set on the lawn and the 18-wheeler on the highway next to you all have one thing in common -- they have parts made at Impulse Manufacturing in Dawsonville, Ga.
The company that began in 1982 as a provider of children's coin-operated rides in shopping malls has become one of the most high-tech precision metal fabrication houses in the country. A recent expansion brought the company to Quick Start for help training employees in cutting-edge processes. Lanier Technical College will provide ongoing training support.
"It's been a great experience working with the Quick Start team," said Ron Baysden, president of Impulse Manufacturing, at recent signing ceremonies. "We want to continue to be a premier metal fabrication house, and to do that, we need the best people and training possible."
"We're honored to be here," said Jackie Rohosky, DTAE assistant commissioner of economic development programs. "We're looking forward to doing a lot more training with you as you continue to grow."

Keeping Their Cool -- Representatives
from Quick Start, Middle Georgia Technical College and Richmond Cold Storage met recently to sign an agreement to provide training for the company's employees at its Perry distribution center for Perdue Farms products. Pictured are, from left: Marla Lowe, Quick Start executive director of economic development programs; Bruce Meilhammer, manager of the Richmond Cold Storage facility; and Dr. Ivan Allen, Middle Georgia Tech president.

Got It Covered
Fiberglass specialists L.F. Manufacturing recently opened a new manufacturing facility in Waycross, Ga. The Texas-based company will produce manholes, manhole inserts and wet wells at the 83,000-square-foot Ware County plant, initially creating about 40 jobs.
Quick Start and Okefenokee Technical College will work together to help build and train a team of employees for the company.
"We are proud to be able to offer follow-up training after the conclusion of the Quick Start customized training services project that will help to create and keep jobs in Southeast Georgia," said Dr. Gail Thaxton, Okefenokee Tech president, at a recent training plan signing ceremony. "We look forward to a long and productive relationship with L.F. Manufacturing."

From left: Jan Melcher, Quick Start director of eastern operations; David Johnston, L.F. Manufacturing vice president of operations; and Dr. Gail Thaxton, Okefenokee Technical College president.
Quick Start News g Spring 2007 5

Events

Creating Super Power

Trojan Battery Company

recently began its sixth Quick

Start partnership. With ongoing

support from Sandersville Techni-

cal College, Quick Start will train

employees at the company's new

140,000-square-foot Sandersville

production facility.

"Quick Start is just fantastic,"

Phil Baker, senior vice president and general manager for Trojan Battery, said at recent training plan signing ceremonies. "They've provided everything from `Batterymaking 101' to visual aids for our

From left: Leigh Evans, Sandersville Technical College vice president of economic development; Marla Lowe, Quick Start executive director; Phil Baker, Trojan Battery senior vice president and general manager; and Lloyd Horadan, Sandersville Tech president.

plant floor."

The Sandersville site, in addition to existing facilities in California and Lithonia,

Ga., will help the company meet increasing demand for its batteries -- used in golf and

utility vehicles, boats and RVs, renewable energy systems, aerial work platforms, and

commercial and industrial floor-maintenance machines.

Keep on Truckin' -- Blue Ridge Manufac-
turing recently opened a new facility in Blue Ridge, Ga., where the company's flatbed, stake, dump and landscape truck bodies will be fabricated. Quick Start will provide training for the new employees, and Appalachian Technical College will provide ongoing support. The agreement was recently sealed with a signing ceremony and a handshake. From left: Charles Rayside, Blue Ridge Manufacturing president; Jeff Lynn, Quick Start director of northern operations; and Dr. Sanford Chandler, Appalachian Tech president.

Aquafil Covers New Ground
Fifty years ago in Arco, Italy, Carlo Bonazzi purchased five sewing machines and his family got busy making synthetic raincoats. From this successful enterprise, the Bonazzis expanded into designing and manufacturing their own fabrics. Today, Gruppo Bonazzi's Aquafil division is a worldwide

organization that produces synthetic fibers used primarily in carpet manufacturing.
Aquafil, which began manufacturing in Cartersville, Ga., seven years ago, recently dedicated a new, 142,000-square-foot building at the facility, creating 72 jobs.
"The inauguration of this new plant is proof of Aquafil's commitment to be here for our American customers, partners and vendors, playing by their rules, in their own backyard," said Aquafil USA
President Franco Rossi at recent grand-opening ceremonies. "The opening of Aquafil USA's Cartersville plant is an important milestone for us and for other Italian
Carlo Bonazzi (left), Aquafil founder and chairman of the board, shows guest Franco Zanibellato some of the synthetic fiber produced at the Aquafil USA Cartersville facility.

Franco Rossi, Aquafil USA president, speaks at the company's grand opening.
companies expanding into the United States, and we must thank Quick Start for the training that helped to make this possible."
"For growing, successful companies like Aquafil, Georgia offers unprecedented opportunities and incentives, a diverse population and excellent market access," said Angela Della Costanza Turner, the Honorary Italian Consul of Atlanta. "It is truly an ideal place to be."

6

Structures of Olympic Proportions

The 2008 Summer Olympics will bring the world to Beijing. And a Georgia company will put a roof over their heads.
Rincon-based TEMCOR designs, manufactures and erects architectural enclosures, including a structure that will house an Olympic swimming complex in Yiwu, China, and several other domed structures for Olympic events.
Recently, to keep up with growing demand for its products, the company installed new, highly automated equipment. Quick Start's ability to work with existing industries that are upgrading technologies helped make the project so successful that

TEMCOR now plans to hire 25 additional employees.
"Quick Start is an invaluable asset to any new company and any existing, expanding company," Leland Sanders, TEMCOR vice president of manufacturing, told
the Savannah Morning News. "Where else can a company get that level of assistance in growing a new workforce into a

manufacturing facility that uses processes not necessarily common throughout the industry?"
TEMCOR was also recently named Georgia's 2007 Manufacturer of the Year in the small-business category for companies with 150 employees or fewer (see story p. 16). The company was nominated by workforce partner Savannah Technical College.

Top photo: A TEMCOR employee operates a machine press to fabricate gusset plates used in the assembly of TEMCOR's architectural dome structures. Bottom photo (from left): Dennis Hansen, TEMCOR director; Chuck Miller, TEMCOR chairman of the board; Dr. C.B. "Bix" Rathburn, Savannah Technical College president; Leland Sanders, TEMCOR vice president of manufacturing; Jan Melcher, Quick Start director of eastern operations; and John Henry, Effingham County Industrial Development Authority CEO.

Foam Home Latexco, Europe's leading maker of latex foam bedding
products, signed a training agreement recently with Quick Start and North Georgia Technical College. The Belgium-based company is locating a production facility in Franklin County and expects to employ approximately 40 people to make the company's high-end products for America's consumer market. At the event, Sam Van Steenbrugghe, Latexco's plant manager, explained that the company's advanced products are made through a complex manufacturing process that requires highly trained associates. "That's why we're glad there's a program like Quick Start to help our people," he said. From left: Jeff Lynn, Quick Start director of northern operations; Sam Van Steenbrugghe, Latexco's plant manager; and Dr. Ruth Nichols, North Georgia Tech president.

Quick Start News g Spring 2007 7

Events

From left: Willis Potts, Greater Rome Chamber of Commerce; Jackie Rohosky, DTAE assistant commissioner of economic development programs; Rep. Paul Smith; Tom Bennett, Floyd County Commission; Ronnie Wallace, Rome mayor; Dwight Stout, Greater Rome Bank president; Tom Caldwell, Greater Rome Bank CEO/ chairman of the board; Roger Manis, Scott Logistics general manager; and Diane Manis, Scott Logistics owner.

`Mom-and-Pop' No More

In the fast-moving transportation services business, there are two choices -- speed up or get out of the way. Scott Logistics is moving rapidly ahead, having progressed from two phones and two computers in 1995 to a $40 million company that recently broke ground on a 24,000-square-foot office facility in Rome, Ga.
"Quick Start is an integral partner in Scott Logistics' growth," explained

owner Diane Manis. "Before, we flew by the seat of the pants, but now with Quick Start's training programs, we have been able to transform ourselves from a `mom-and-pop' into a corporation of professionals."
Since April 2006, Quick Start has trained over 100 logistics coordinators, account managers and staff for Scott Logistics, making use of 23 different training courses. Plans for growth will continue to keep Quick

Start and training partner Coosa Valley Technical College on the move.
"Scott Logistics' rapid growth and success make it an asset to Rome and to all of Georgia, which it represents through its national and international transportation operations," said state Rep. Paul Smith, who participated in the recent groundbreaking. "Scott Logistics' new facility is a proud accomplishment for all of us."

Raymond Albritton, WILO-EMU USA production manager, at the company's Thomasville headquarters.

Pump Up the Volume
"Pumpen Intelligenz" (pump intelligence) is the motto of WILO EMU, manufacturer of heavyduty municipal and industrial pumps and mixers. With its emphasis on "intelligenz," it's no wonder that the German company made the smart choice of turning to Quick Start and workforce partner Southwest Georgia Technical College for training assistance when installing new technology at its North American headquarters in Thomasville, Ga. "The new assembly processes require testing for all pumps and mixers in the new test facility," said Dr. Glenn Deibert, Southwest Georgia Tech president. "This new testing area utilizes new technology consisting of variable frequency drives for motor operations, PLC-based pump controls and data collection. "Most of the jobs that develop within our state are expanding positions with existing companies," Deibert added. "We're really happy to have Quick Start help us with that."

8

Making a Good First Compression

Ancient ritual stood alongside the latest advanced manufacturing technology when TD Automotive Compressor Georgia LLC (TACG) held its grand opening in November.

Matsuriza, an ensemble performing traditional Japanese drumming, was the highlight of a ceremony that included TACG President Masaharu Suzuki, TICO President Tetsuro Toyoda, DENSO President Koichi Fukaya and Georgia's Lt. Gov. Casey Cagle.

TACG's 344,000-square-foot facility in Jackson County, Ga., has the capacity to produce 2 million auto compressors a year.
During the ceremony, Quick Start was recognized for its contribution to TACG's success. Training courses have included subjects ranging from "5S - The Visual Workplace," to safety, refrigerant circuits and compressors, and "Working with the Japanese for U.S. Americans."
"Georgia's Quick Start program is a tremendous asset in these projects," said Cagle.

Left: Matsuriza, a traditional Japanese drumming ensemble, performs at the TACG grand opening. Inset: Masaharu Suzuki, president of TD Automotive Compressor Georgia LLC, presents DTAE Assistant Commissioner Jackie Rohosky with a plaque honoring Quick Start's contribution to TACG's workforce training. Quick Start Training Coordinator Paul Helton stands at left.

Clear Sailing in South Georgia

Grady County recently netted 60 new jobs when

Seminole Marine expanded the Cairo facility where its

popular Sailfish line of saltwater fishing and pleasure

boats are made. The company added two new 30-foot

vessels to its fleet, and turned to Quick Start for

training assistance and Southwest Georgia Technical

College for ongoing educational support.

"Since Seminole Marine has expanded rapidly, the

requirement for trained employees and documented

formal training procedures has become paramount,"

said Dr. Glenn Deibert, Southwest Georgia Tech presi-

dent. "In order for them to maintain their high quality

standards and still meet increased demand, assistance

from Quick Start was needed."

"I think the Quick Start program is a great tool for Georgia," said Paul Hoppes,

From left: Paul Hoppes, Seminole Marine president;

Seminole Marine president. "It gives the employer an advantage by having available the training you need to be in business and

Dr. Glenn Deibert, Southwest Georgia Technical College president; and Joe Bailey, Quick Start director of

to get employees that you can retain."

western operations.

A Seminole Marine employee applies caulk as a finishing touch on one of the company's saltwater boats.
Quick Start News g Spring 2007 9

Cover Story

Continued from page 1

Rolls of high-quality paper are the first ingredient in Oracal film. Below (from left): Uncut rolls of film; an employee removes rolls of film that have been cut and are ready to ship; Quick Start PLC and process training helps employees run and maintain high-tech equipment; Oracal's Black Creek, Ga., facility.

"We've been working very closely since the beginning with the officials of Bryan County, and there's never been a `no' or `we'll put you on hold,'" says Hersacher. "Everybody tries to solve the problems and tries to help you. This makes a big difference."
Today, the 260,000-square-foot facility has approximately 85 permanent employees, and the machine operators have gone through Quick Start training, which has ranged from quality and safety to Siemens PLC and manufacturing process training. Now, as the growing company's hiring shifts into a new phase, the training needs have also shifted. One of Quick Start's latest projects involves developing a company orientation video that can be used as individuals are added to the Oracal team.
"At the moment, we're hiring two or three or five operators at a time," says Hersacher. "An orientation video helps to provide consistent training to get them up and running."
Film stars
Orafol, Oracal's parent company, is a global leader in self-adhesive PVC graphic film manufactured for uses such as reflective signs on the highway, billboards, and the faux paint jobs on today's race cars and emergency vehicles.
To make its signature product, the company first coats high-quality

10

Oracal films can be digitally printed and used to make signs (top photo) or wrap vehicles like these Fire Department of New York emergency trucks (bottom photo).

paper with silicone. Then the silicone paper is coated with adhesive and laminated with film. The laminated film is then wound on a roll, cut to the customer's specified size, wrapped, packaged and shipped -- all within 24 hours of receiving an order.
The operation runs smoothly thanks in part to Quick Start training. As the company expands, with plans to add another line every year, Quick Start will continue to provide programs specific to Oracal's equipment and processes. In fact, new technology is scheduled to go online later this year, and plans are already in the works for Quick Start to help get a new team up to speed.
"We really love the way Quick Start comes up with ideas -- they think along our lines and have an open ear for our needs," says Hersacher. "All of the training material they've pro-

duced for us is so high-end. We're very happy with Quick Start."
And Bryan County is happy with Oracal, which has taken extra effort to make the plant environmentally friendly. It is a self-sufficient facility, using a limited amount of natural gas to start the process. The plant then creates thermal energy by incinerating nearly all of its own emissions.
"By burning our own exhaust, we use no natural gas and release only CO2 and H2O into the air," says Hersacher. "The air coming out of this plant is actually cleaner than that going in."
"Oracal represents everything that is desirable in an economic development project," says Dr. C.B. "Bix" Rathburn, president of Savannah Tech. "Oracal is the kind of corporate expansion every community in the country wishes it could attract."
"Bryan County and the state of Georgia have proven to be excellent partners in realizing our vision of manufacturing in the United States," says Ben Philips, president of Oracal USA. "The Quick Start program is an ideal resource that we are blessed to have available to us to help make Oracal's rapid growth sustainable over the long term."
Obviously, Oracal has found a permanent home in Bryan County and is making it stick.

From left: Barry Grove, Quick Start training coordinator, presents samples of safety posters to Christian Hersacher, Oracal director of manufacturing engineering.
The Art of Training
Nearly all Quick Start projects require the production of high-quality, effective visual materials. To ensure that these training products are custom-designed for each client company, the five Quick Start offices around the state have teams of graphic designers, illustrators and desktop publishers that produce materials tailored for a company's exact needs.
At Oracal, for example, Quick Start's Savannah office created a series of posters to help bring training messages onto the plant floor.
"Training aids like banners, displays, brochures or these posters are powerful tools to reinforce the message that the trainers are delivering," says Luis Gaybort, Quick Start senior graphic designer. "They provide simplicity, association, repetition and communication of the key messages
from the classes."

Metal and Plastics Sector
A Katy Company

From top center: Glit/Microtron's Wrens, Ga., facility; color samples of Glit's nylon buffing pads; Glit's kaizen team leader Patrick Lee outlines the "current state" value stream map of Glit's production processes; the "future state" value stream map illustrates the number of inefficient activities eliminated through ongoing "continuous improvement" kaizen events.
12

When Rayne Johnstun took charge as general manager at Glit/Microtron in Wrens, Ga., he knew he had his work cut out for him. The business

was losing money. Nearly 300 jobs were at risk.

"There had been a lot of turnover in management over the previous few

years," Johnstun recalls, "and a lot of newcomers needed to get on the same page."

The problem wasn't in the products made at the plant. Glit makes abrasive

pads for the industrial market, in addition to a range of consumer products

such as abrasive sanding items, sponges and scouring pads.

The problem was that production processes for making the popular items

-- from ordering the raw materials to labeling the end products -- lacked the

right amount of efficiency for the company to turn a profit.

Johnstun knew what had to be done: Go lean!

Johnstun decided to perform a complete assessment of all the factors shap-

ing the company's processes. He called Quick Start for help.

"We began our lean journey by coming up with an

overall vision of where we needed to go," Johnstun ex-

plains. "We charted our long-term objectives and linked

those to what we needed to accomplish in 2006."

To track their progress on the lean journey, Quick Start

helped Johnstun's team equip themselves with such tools as

Microsoft Excel. The company refurbished rooms at the

plant to serve as "command centers" for holding meetings

and posting charts and graphs to track performance.

"If you're not keeping score, you don't know how

you're doing," Johnstun says. "We had to start track-

ing our processes to get the data so

Customer

Future State Non-Woven (Hand, Floor Pads- GAF) Product

Demand

Value Stream Map

TAKT

we could measure performance and success."

Business Case

Value Statement

Key Requirements

Measurements

Ideal State

They then began training the team

on the various conceptual tools needed

PRMS

PRMS

PRMS

PRMS

PRMS RF

PRMS RF

to execute a lean manufacturing strat-

Milk Run

Forklift

Forklift

Forklift

Supermarket -50%
Supermarket Boxes

Put full loads Pallet, trolley Into footprint

Supermarket Barnyard -50%

Forklift

Pull order

Pull to Truck
RF

egy: 5S, Six Sigma, and -- central to their process -- kaizen, the philosophy of "continuous improvement."
"We presented the kaizen event

process as a tool and vehicle for roll-

ing out changes," Johnstun says. "But we didn't know where

to start. We didn't want a shotgun approach to doing things.

There's a better way, and that is to map the process and identify

what you want to target. This is one of the first things we did.

From there we created the value stream map."

Value stream mapping is a key concept of lean manufacturing

-- users create a diagram to illustrate the flow of materials and

information through the process. Glit's value stream map identi-

fied all the spots in the process where value was added to the

product, and, in turn, where there was wasted effort.

Once the company knew where they wanted to go, Quick

Start helped them get there.

"We did a project study last April and began training at the

end of that month," says Eddie Fite, Quick Start training manag-

er. "We sat with them for a whole week before we got started to

see what we needed to include in the training in order to prepare

them the best for the kaizen events to come."

A series of "kaizen events" was held to focus on different

areas in the production process. An essential part of the analysis

is based on measuring performance metrics on a regular basis.

"We explained to

our team that we

measure performance

every hour because, if

you hit your target

every hour, you'll hit it

for every day, then for

every week, and then

hit it for the month,"

Johnstun says.

And hit the target

they did.

In 2004, it took

Glit/Microtron General Manager Rayne Johnstun

21 days for an order

reviews the improved steps in the process for making labels for the facility's wide variety of products.

to ship. By the beginning of 2007, it was

down to five days. In 2005, the company was losing money. In

2006, they broke even. Today, they're making money.

The improvements were so dramatic that Glit's parent company

moved the operations of another separate plant to consolidate with

the Wrens operation.

"Quick Start has been a tremendous help getting our people

ready to make these changes," Johnstun says.

He concludes that the ultimate measure of success is that

Glit/Microtron is still in Wrens, and still thriving.

"Looking back at where we started, we see that we might have

had turnover, but now we have improved productivity," he says.

"Today, we have 270 secure jobs, rather than 320 jobs

at risk."

Right, from top: At Glit's Wrens facility, nylon is first spun into large rolls; a Glit associate inspects the product for flaws; pads are cut, stacked, packed and shipped to customers.

Quick Start News g Spring 2007 13

Automotive Sector

Shifting into Overdrive

Honda Precision Parts of Georgia revs up with Quick Start

"Contamination is the enemy," says
Jennifer Kemp, human relations administrator at Honda Precision Parts of Georgia (HPPG), as she exits an air shower -- a booth of air jets that blow any loose debris from the hair, clothes and skin of entrants to the company's assembly line, which

is a clean-room environment. "A little speck could contaminate the transmission and prevent proper operation and shifting."
The automotive environment is a fast-paced one. Hours after assembly, Kemp says, the transmissions being made in Tallapoosa, Ga., will be sit-

ting inside Honda Odyssey minivans and Pilot SUVs in Lincoln, Ala., 60 miles away.
"Honda chose Tallapoosa for this facility only partly because of its proximity to the assembly plant," Kemp adds. "Another reason is the really capable workforce here that was created by the textile industry."
The company opened the Tallapoosa facility, Honda's 13th in the United States, in 2005, and chose Quick Start as a partner for building and training its team.

"Quick Start ... made their
programs specific to our
operations, which helped
immensely."
John Spoltman HPPG Vice President
Since then, Quick Start has trained HPPG associates in core skills like safety and blueprint reading, jobspecific skills like the assembly process and operational procedures, and advanced manufacturing techniques like PLCs and robotics. But employees have also practiced collaboration skills and received quality, productivity and leadership training running the gamut from diversity in the workplace to lean manufacturing.
Even the people-oriented, softskills training has paid off, according to John Spoltman, HPPG vice president. "Thanks to the support we've

Top photo (from left): Honda Precision Parts of Georgia associates Jewell Stephens and Bobby Graham install parts on a Honda transmission as it proceeds down the assembly line. Bottom photo (from left): HPPG associates Dacha Beal and Marcus Ware work in the company's third clutch install process area.
14

HPPG associate Billie Florence on the company's transmission assembly line, which is a clean-room environment.

"We try to make very clear up front what each associate can expect when they come to work for Honda," says Spoltman. "Quick Start really supported that and made their programs specific to our operations, which helped immensely."

Into the future

gotten from Quick Start, we feel very confident in our associates' capabilities," he says. "Their knowledge of transmissions and the function of the mission in some cases is better than the associates at our parent facility in Ohio -- just because we go through the extra steps of the softside training."

Meanwhile, in a classroom away from the assembly line, other HPPG associates are manipulating animated robots on a computer screen. But they're not playing video games. They're taking part in a Quick Start Robot Operator Training class, learning to take a part-moving robot through its paces in the classroom

From the beginning

Quick Start's involvement with

the HPPG team began even before

the first associates

were hired. "I never antici-
pated what a benefit

Top left photo: HPPG's Tallapoosa, Ga., facility. Top

the pre-hire training was for the job candidates," says Kemp.

right photo (from left): Associates Charles Windsor and David Herndon

"When I first heard about it, I could only think of the benefits to the company from spending more time with the candidate; but after I saw it, I re-

operate virtual robots during Quick Start's Robot Operator Training class. Bottom photo: HPPG associate Adam Rowell operates the real

alized that it gave the candidates the ability to better choose their

version of the leak-testing robot simulated in class.

next employer."

Before being selected for employ-

ment at Honda, candidates not only

got a classroom introduction to Honda

and its mission and philosophy, they

also participated in a hands-on trans-

mission assembly exercise and

team-building exercises.

before moving on to the real thing on the plant floor.
These associates will work in a new area about to go online at the facility. An aluminum processing department is being created so the company can manufacture four of the more than 400 parts in its transmissions.
"We bought our robot, and Quick Start developed training based on that specific robot," says Spoltman. "That's the kind of thing that's stood out for me the most throughout this partnership -- how Quick Start has been able to tailor classes to meet our specific needs. Quick Start's support has really helped us build a team of knowledgeable, capable associates."
Quick Start News g Spring 2007 15

State Celebration

Progress Reported

The 13th Annual Manufacturer of the Year Awards

Manufacturing is alive and well in Georgia, still the bedrock of the state's economy. That was the message at the 13th annual Governor's Awards Luncheon held this past April at the Cobb Galleria in Atlanta.
"[T]hrough integrity, innovation, commitment and -- we often tend to overlook this one -- good old-fashioned hard work, manufacturing can, does and will continue to succeed in Georgia," Master of Ceremonies Wes Sarginson said to an audience of more than 1,200 friends of manufacturing, one that counted among its distinguished numbers keynote speaker, Gov. Sonny Perdue.
"Georgia manufacturers don't just watch progress take place," said Perdue. "You're some of the ones who make it happen."
Ron Jackson, DTAE commissioner, introduces the 2007 MAW Governor's Awards Luncheon.

The luncheon, co-hosted by the Georgia Department of Technical and Adult Education and the Department of Economic Development, was the main attraction of Manufacturing Appreciation Week, which is held each year to show support for Georgia's manufacturing sector.
At this year's event, Richard Kopelman, a partner with accounting firm Habif, Arogeti and Wynne, presented the findings of the firm's biennial manufacturing survey. The results showed optimism among Georgia manufacturers.
"Ninety percent of respondents said Georgia is a great place to conduct business," said Kopelman. He added that respondents indicated the state's greatest strengths were in its transportation network and low cost of labor.
The highlight of the Governor's Awards Luncheon was the announcement of the 2007 Manufacturers of the Year, beginning with Rincon's TEMCOR in the small company category (150 employees or fewer).
"I'd like to thank you for your recognition of TEMCOR as a world-

From left: Ken Stewart, Georgia Department of Economic Development commissioner; Gov. Sonny Perdue; and Mr. Eui Hwan (Eddie) Jin, Kia Motors Manufacturing Georgia senior director.
`Georgia manufacturers
don't just watch progress
take place ... they make
it happen.'
Gov. Sonny Perdue
class manufacturer," said Leland Sanders, TEMCOR vice president of manufacturing. "I'd like to thank the Department of Technical and Adult Education, particularly Assistant Commissioner Jackie Rohosky, Jan Melcher, and the rest of the Quick Start staff, for your continued efforts to support TEMCOR."
Lawrenceville's Ricoh Electronics won the award in the medium company category (151 to 749 employees). Frantz J. Pierre, vice president of toner business operations and plant systems management division, accepted the award. "We

16

Sponsors

are honored, but more importantly, we are humbled to be the recipient of this prestigious award from our beloved state of Georgia," he said. He added that Quick Start was instrumental in Ricoh's choice of Georgia for a facility. "I hope that Ricoh's partnership with Georgia Quick Start will last for many years to come."
The prize in the large company category was captured by Perry's Perdue Farms Inc. facility. "It was a great decision on our company's part to come to Georgia," said Jim Perdue, company chairman and CEO. "This facility is quickly becoming our flagship operation, and we're in about 14 states."
"We're really not in the chicken business, we're in the people business; we couldn't do it without our associates," Perdue added. "Quick Start has been a tremendous tool to help us get our associates fully trained before starting their jobs."
Triple Crown Winner

In the student design contest, nine students received scholarships for their artwork in placemats, posters and t-shirts depicting their vision of Georgia's manufacturing community. Kolyse Eliza Wagstaff from Covington won first prize in the placemat competition; Justin Dunbar from Watkinsville took the t-shirt category; and Jackson's Tyler Van Dusen won the poster division. Each was presented with a $500 scholarship. Second place winners of $300 scholarships were: Tywun Jackson of Americus, placemat; William Richard Craven of Conyers, t-shirt; and Caroline Penhallegon of Thomasville, poster. In third place, Haley Noelle Almodovar of Martinez, Amanda M. Wilson of Barwick and Brittany D. Meeks of Soperton each received a $100 scholarship in the placemat, t-shirt and poster categories, respectively.

From left: Ron Jackson, DTAE commissioner; Jim Perdue, Perdue Farms chairman and CEO; Richard Jamison, Perdue Farms complex manager; Richard Rateau, Perdue Farms director of operations, prepared foods; Gov. Sonny Perdue; and Ken Stewart, Georgia Department of Economic Development commissioner.
From left: Ron Jackson, DTAE commissioner; Frantz J. Pierre, Ricoh Electronics vice president of toner business operations and plant systems management; Terry Herbert, Ricoh Electronics vice president of thermal media group operations; Gov. Sonny Perdue; and Ken Stewart, Georgia Department of Economic Development commissioner.
From left: Ron Jackson, DTAE commissioner; Jorge Sepulveda, TEMCOR shipping operations and training specialist; Leland Sanders, TEMCOR vice president of manufacturing; Mat Carmichael, TEMCOR shipping supervisor; Gov. Sonny Perdue; and Ken Stewart, Georgia Department of Economic Development commissioner.

Jackson's Tyler Van Dusen ought to be on a first-name basis with Gov. Sonny Perdue by now. The 14-year-old took first place in the MAW student design competition for an unprecedented third time this year. In 2004, he won the placemat competition, and 2005 marked his first victory in the poster competition.
Presenting Van Dusen with his second first-place award for poster design, Jerry Silvio, vice president of Pattillo Construction Company, noted, "With four more years left in high school, he should be able to accumulate enough scholarship money to pay for at least his first year of college."
With plans for a career in architecture, Van Dusen, who currently attends Henderson Middle School, should be able to put his three $500 first-place scholarship checks to good use.
"Georgia manufacturers are appreciated," Van Dusen says of his dedication to the MAW design contest. "It's like I said the first year in my art, `God bless Georgia manufacturers.'"

Above (from left): Tyler Van Dusen, poster design winner; Gov. Sonny Perdue; Justin Dunbar, t-shirt design winner; and Kolyse Eliza Wagstaff, placemat design winner. At left: Van Dusen in 2004 and 2005.

Quick Start News g Spring 2007

17

Service Industry

Make the Call

ProCore Solutions meets challenges with Quick Start training

In a Chattahoochee Technical College classroom, students bound around the room waving sheets of paper. "Three P in a HG? Anyone got three P in a HG?" someone calls out. "Who knows 26 M in a M?" asks someone else.
Sounds like a bingo game gone awry, but it's actually a puzzle-solving exercise that helps newly hired, front-line call-center employees for ProCore Solutions learn the value of teamwork. The students are among the more than 100 employees hired recently after the company won a contract to handle inbound sales and customer-
" ... what Quick Start did in designing and delivering a training program has literally saved hundreds of thousands of dollars."

care calls for utility provider Gas South.
"We can already see

Greg Steele (far right), president and COO of ProCore Solutions, praises a successful training partnership. Front row (from left): Sandra Morris,

results in quality thanks to the Quick Start training," says Lauren

Quick Start director of performance technology; Alex Ferdinand, Chattahoochee Technical College vice president of economic development;

Slaughter, ProCore's director of training and development. "Quick

Jackie Rohosky, DTAE assistant commissioner of economic development programs; and Mary Fornoff, Quick Start training coordinator. Back row:

Start spends a lot of time talking about handling the customer, being customer-focused.

Lauren Slaughter, ProCore director of training and development, and Derrick Williams, ProCore training specialist.

We've seen direct, solid, positive results in that customer

experience area. I attribute that to the training."

Greg Steele, ProCore Solutions President and COO

ProCore Solutions employee Timothy S. Edwards takes a customer call.

18

Training at work
At ProCore's state-of-the-art Marietta call center one week later, the situation is similar to that in the classroom -- only no pseudo-bingo. This time it's for real. As the new employees take calls from customers and potential customers of Gas South, they find themselves occasionally putting their heads together to solve problems handling everything from billing to how to sign up for Gas South service.
"If your people are confident, they'll take on any challenge you give them; and when this group sat down, they were confident," says Tyndall Chapman, ProCore director of client services. "They had good

"We can already see

results in quality

thanks to the Quick

Members of the ProCore Solutions team participate in a Quick Start class in "Managing Difficult Situations."

Start training."

employees through Certified Customer Service Specialist

Lauren Slaughter, ProCore Solutions Director of
Training and Development

courses," says Alex Ferdinand, Chattahoochee Tech vice president of economic development. "In fact, ProCore was the first time we offered CCSS classes specifically for one

company -- something we do all the time now."

training and they knew that if anything came up, they

At one time, more than 60 percent of ProCore employ-

could handle it."

ees were trained through the CCSS program. Attesting to

And they did. According to Greg Steele, com-

its value as a retention tool, many of them are still with

pany president and chief operating officer, ProCore

the company.

Solutions almost immediately began outperforming

"You can definitely see the results of the CCSS train-

Gas South's previous call center on both percentage

ing in lowered attrition; many of our customer service

of sales made per call and amount of time spent on

representatives who went through the program are still

each call.

here," says Slaughter. "Many of them went on to take

"A shorter time per call tells us our employees

leadership roles because they have solid quality metrics

went through training and know how to handle a

attributable to that program."

customer," says Steele. "On their first day, we went

Ferdinand agrees that investments in training pay

from eight minutes per call to six and a half. With

off. "Retention is largely based on how employees

3,000 calls per day on average, what Quick Start did perceive the investment of a company back into its

in designing and deliver-

employees," he says.

ing a training program has

At a luncheon the

literally saved hundreds of

company held to show

thousands of dollars."

appreciation to the Quick

Tradition of training

Start team, Steele summed up what the relationship has

Chattahoochee Tech and

meant to him. "We're proud

Quick Start have been part-

that our employees were

ners with ProCore Solutions

trained through Quick Start.

ever since it began and grew

It's a sense of pride for me

from about 11 to nearly 300

that we have this relation-

employees.

ship," he said. "What Quick

"The company was formed

Start has delivered was

in 2000, and almost immediately they began sending their

ProCore's Marietta, Ga., facility.

above our level of expectation. It worked."

Quick Start News g Spring 2007

19

DELIVERY SYSTEM
33 Technical Colleges With Multiple Campuses 4 University System Colleges With Technical Divisions

Ron Jackson, Commissioner Georgia Department of Technical
and Adult Education www.georgiaquickstart.org

Quick Start Project Announcements

... Serving communities throughout Georgia

Atlanta: Barbour Corporation is creating 25 jobs at a marine extrusion facility.

Rock Spring

Lithia Springs: Office furniture company Steelcase is hiring 100 new employees.

Augusta: Automated Data Processing Inc. (ADP) is building a new customer solutions center, creating 1,000 jobs.
Bainbridge: Manufacturer of residential and industrial storm windows TRACO is hiring 125

Ball Ground

Monroe: Leggett & Platt is expanding its facility for

Flowery Branch RockmartDuluth Suwanee

producing mattress springs, creating 18 jobs.

Atlanta

Buchanan

Monroe

Lithia Springs Covington Lincolnton

Newnan: Retailer PetSmart is creating 300 jobs at a facility for warehousing and distributing

Newnan

Warrenton

pet products.

new employees.

Sandersville

Perry: Richmond Cold Storage is creating

Ball Ground: Transtechnik, a manufacturer of power distribution systems, is creating 50 jobs.
Black Creek: Oneida Limited is opening a new ware-

Statesboro 120 jobs at a new food distribution facility.
Swainsboro

Perry

Black Creek

Rock Spring: Manufacturer of automotive

Savannah brake assemblies Nissin Brake Georgia is

house for its stainless steel flatware and tabletop

hiring 80 new employees.

products, creating 150 jobs.

Rockmart: Engineered Fabrics Corporation,

Buchanan: Japanese steel manufacturer and proces-

Homerville

maker of fuel tanks for aircraft, is creating

sor Suzukaku is creating 50 jobs at its facility for

Bainbridge

100 jobs.

manufacturing handlebar assemblies for Yamaha.

Sandersville: MeltBlown Technologies, manu-

Columbus: Beverage bottling company Buffalo Rock is

facturer of meltblown polypropylene, is creating

hiring 30 new employees.

90 jobs at a new facility.

Covington: C.R. Bard Inc. is creating 45 jobs at a medical devices distribution center.

Savannah: Retailer IKEA is creating 125 jobs at a new warehouse and distribution center.

Covington: Oldcastle Glass, maker of windows and doors, is creating 50 jobs.

Statesboro: Viracon is expanding its facility for assembling highperformance fabricated glass windows, creating 70 jobs.

Covington: Saint-Gobain Desjonqures is expanding its glass-blowing facility, creating 30 jobs.

Suwanee: Maker of automotive electronic safety systems Elesys North America is hiring 50 new employees.

Duluth: Pharmacy benefits management company Cypress Care is creating 60 new jobs for an expanding customer service facility.

Swainsboro: Vista Window Company is hiring 55 employees at a new facility for manufacturing vinyl windows.

Flowery Branch: TRW is creating 125 jobs at a facility for machining and assembling caliper brake systems.

Warrenton: Maker of corrugated plastic drainage products Plastic Tubing Industries Inc. is creating 30 jobs.

Homerville: B-Way Packaging, maker of specialty cans, ammunition boxes, paint cans and steel pails, is expanding, creating 58 jobs.

Warrenton: TRW Automotive is creating 197 jobs at a new facility for manufacturing automotive brake drum castings.

LaGrange: American Home Shield, the leading company for home warranties, is adding 75 new jobs this spring.

Waycross: L.F. Manufacturing Inc., maker of molded fiberglass components, is opening a new facility, creating 40 jobs.

Lincolnton: Medac, an anesthesiologist billing specialist, is building a customer service center that will provide 100 new jobs.

Georgia Quick Start Centergy One 75 Fifth Street NW Suite 400 Atlanta, GA 30308