Lean Champs: Our catalyst to go from Good to Great
We have all heard that you need to involve your employees to be successful with Lean. And that being said, what does it truly mean to involve your employees?

Polycon had implemented a number KanBan systems with success. When they got to systems that required operator engagement for successful sustain, they struggled. On reflection, they realized the systems belonged to their leadership team not their operators. To change that ownership, Polycon decided to utilize operators from the floor to facilitate our Lean implementation. This new role, Lean Champions, was Polycon’s catalyst to grow from Good to Great.

Polycon had a 5S system but it was not sustained. The 8 Lean Champs were challenged with developing and implementing a 5S system that would be sustained by the entire plant of 1000 people. They were asking operators from the production floor to stand up in front of their peers to teach and rollout 5S. They were up to the challenge and had completed a successful implementation on the plant floor in 6 months.

The next step for Polycon was to tackle standardized work. Once again the Lean Champs were challenged to develop and implement a sustainable standardized work system. Polycon utilized a 5 day Kaizen Blitz’s format as the forum to implement standardized work and the Lean Champs were the facilitators.

Polycon has benefited from having Lean Champs be the driving force for Lean on the production floor. They still have challenges with sustaining but they have pockets of excellence with in our facility.

Going from Good to Great was only achievable through their Lean Champs. This presentation will explain how Polycon went from good to great.

Polycon Industries is a leading edge mould, paint and assembly facility which produces bumper covers for major automotive manufacturers. As part of its total bumper system capabilities, Polycon is the only fascia producer that also manufactures expanded polypropylene foam energy absorbers. Technology, capability and people coupled with continuing forward vision are Polycon’s major resources as it faces the future. Polycon is a company focused on Customers, Employees and Shareholders to be the best.

Marnie Allen, P.Eng. MBA

Marnie Allen has 15 years of experience in diverse roles including process engineering, department and business management, development of people, project management and performance management. She has worked in the steel and automotive industries and has led the culture change at Polycon.

Angela Schrum, Six Sigma Black Belt

Angela Schrum has 20 years of experience in various roles in automotive manufacturing. The experiences include manufacturing, continuous improvement, team building and mentoring. Angela has experience in Kanban, 5S, Kaizen blitz, and team training.