Cambridge had the pleasure of hosting a tour for AME presented by Paul Akers. We made a few stops during the tour to show off our “2 Second Lean” improvements around the facility. Here we would like to share some of the examples of employee genius at Cambridge. 

In this video, Johnathan Solter shows off the new carts used to transport units around the facility. They have gone from being clunky carts that must be welded and can only fit specific sizes to a one size fits all cart that anyone in the facility can build. This improvement showcases not only employee genius but the ability of our employees to work in unison across multiple departments. 

In this video, Conner Lalonde shows off the progress at the wiring stations. With the changes, he and others have implemented, the required motion has drastically decreased. As a result, individuals can gather any supplies they need within arm’s reach, plus can move stations should need be. 

In this video, SMegan Solter shows off the secondary RCS station that she put together. SMegan was given free rein to make the area however she would like. She has implemented better shelving, drawers, and organization in her area. 

In this video, Mathew shows off some of the improvements that have been made in the sheet metal department. By stepping up and trying a new cutting method, they have dramatically cut down on the amount of sheet metal waste that comes from forming parts. Mathew also shows off the new way of cutting RCS cans so that defects are less prevalent. 

Employee genius is something that Cambridge takes great pride in. These examples are only but a few of the many that occur. We display each of our improvements every day during our morning meeting. Please join us if you are interested in seeing these changes firsthand.

 

Continuous improvement plays a key role in the Cambridge culture - we are always striving to better ourselves and our processes. After learning about 2-Second Lean from Paul Akers and adopting it in our shop, we then explored the methodology of continuous improvement and found Kata. Most recently employees were introduced to it through the AME 750 and 24-week continuous improvement training. 


The structured practice of continuous improvement, Kata has proven to enhance our lean methodologies and give us the process to see a project through with enhanced outcomes.

In this video, Becca Jenkins does a great job of explaining how our Operations Engineering team uses Kata to improve different production lines and processes. Used first on our S-series HTHV heating line, employees formed teams and came together to create experiments. Through many experiments guided by Kata, we have been able to drastically cut down on the space required to perform tasks while also reducing the number of errors made during our processes. These improvements have been most recently implemented on our new paint line. Using Kata, we have identified ways to improve our line density with quality in mind.  That means we can load more parts in the same amount of space which means better line efficiency. Through Kata experimentation, we have learned how to deliver parts to the new paint line so that the loaders can hang the parts as efficiently as possible in the sequence that makes the most sense for processing the parts after they are painted and unloaded from the line.  These improvements are consistently being made to enrich the lives of our Cambridge colleagues.

During our morning meetings each day we share the latest improvements to give a space for employee genius to be celebrated and inspire other areas of the shop. If you would like to get a glimpse into our Kata process and culture of continuous improvement, please join us for a morning meeting. 
 

Each year, on the first Friday in October, the manufacturing community opens its doors to the public. This is known as Manufacturing Day. Manufacturers try to give insights into the problems and solutions that the modern manufacturer faces. This year Cambridge had the pleasure of hosting an event on creators wanted that provided a glimpse into manufacturing. 

Cambridge believes that everyone has the ability to lead and just needs to right opportunity. We believe in growing our leaders from within using multiple avenues for this development. In the clip below our marketing ambassador, Tony Spielberg, goes into detail as to how we develop leadership across the company. 

The Cambridge Air Solutions brand and our commitment to “Enriching Lives” is more than a name, an icon, or a tag line. It is our promise to our people, our customers, and to our supplies, that Cambridge desires to make an impact on the world. 

Megan Solter, Jesse Hummel, and Thomas Little were panelists and provided a live Q&A segment. They go into detail on their experiences at Cambridge, and the ways in which the culture has impacted them. 

Please join us for a morning meeting if you have any questions, or would like to experience our culture first hand!

No matter the business, quality issues remain a factor. After all, quality impacts all aspects of a business and improving it is a big undertaking. At Cambridge, our method involves a focus on employee genius and continuous improvement.

The problem is in the process, not the individual

Throughout the day, employees track quality issues using a communal iPad. These issues are compiled into a report that is then shared in an open conversation each day with the entire production team. Most issues are presented with a picture and a clarifying description of the problem. Throughout the conversation, there is never a moment of blame or causing shame to an individual for a mistake. Cambridge believes that the process failed the individual. If the proper procedure was in place, then the quality issue would not have occurred. The best part is: the process can be improved.

Quality issues are then archived in order to identify reoccurring issues. Whenever quality issues become repetitive, the process must be evaluated. When this happens, a team of employees steps up to address the issue. Employees volunteer during the quality meeting and come together to find a solution. Rather than a supervisor telling them what they should do in order to fix it, Cambridge believes that those performing the job are the ones who will come up with the best corrective actions. This employee genius will allow for the process to be improved in the most effective way. 

Process improvement in real life 

One example of this was with the orientation of gas train components. There are shutoff valves (SVs) and safety shutoff valves (SSVs) that must be orientated to the correct direction to ensure proper functionality. The SVs and SSVs were configured incorrectly on a few occasions, and there was a significant risk if these components were not correct when shipped out into the field. A team of employees came together to correct this mistake and ensured the process would drive the solution. It was decided that after the gas train was installed, the gas train builder would place orientation indicators on the SV and SSV. Proper orientation now goes through multiple checks ensuring the process will not allow for failure and for an incorrect gas train to make it into the field. 

Making improvement a central idea to culture

Standardized workflows that clarify what must be done help our employees achieve high expectations of a quality product. The perfect people to develop these processes or improve them are those who do it every day by using their employee genius. Open conversations without the fear of punishment allow for all quality issues to be addressed. Cambridge employees understand that there is no shame in making a mistake. Embracing failure and prescribing solutions enriches the lives of our employees and of our valuable customers.

Come and join us

Each morning Cambridge goes over quality issues that had happened the previous day. We discuss what went wrong within the entire organization and share what improvements will be made to ensure it doesn’t happen again. Come and join us for a morning meeting to see this in action!

Often there is a divide between those in the office and those who work on the floor. This divide can seem as if it is a wall that stands between the two parties. Building a strong culture brings unity between the two, but a great culture cannot exist as two separate entities divided by a shop floor wall. Though we have yet to achieve our final goal of breaking down that “wall,” we hope that through continuous improvement we can become that great culture we strive for.

If you think of this process as removing “one brick at a time,” the process began with the dress code. There was an apparent disparity in the way people looked on the shop floor compared to in the offices. Those on the floor had to wear jeans or durable workpants while those in the office were required to wear slacks or other dress clothes. Doing away with this allowed for a more uniform code that made all employees feel like equals.

A focal point of our strategy towards building a solid culture is allowing for employees to utilize their genius. One way this happens is through creating leadership opportunities. At Cambridge, companywide meetings take place every day and provide full transparency into details about company operations - whether it be finances, safety, or delivery timing. These meetings are led by different individuals every day. Employees sign up and are given a chance to lead in front of the entire company. Not having the same higher-ups conducting the meetings every day clarifies that anyone can be a leader, regardless of their official position. 

When working on the shop floor, most of the day is planned for you as there are quotas on production, unlike in the office, where the time utilization is more at the discretion of the individual employee. To ensure that all employees feel as if their ideas are appreciated, time is set away each day for “lean” ideas. This is when the employees on the floor have no task that is required of them, and they are allowed to think of anything that can improve the company freely, whether it be changes to the processes, their workstation, or something that could improve safety. Empowering individuals is a centric idea of this culture and lets it be known that genius exists within every individual. 

One glaring disparity that can cause frustrations between the office and floor is indoor air quality and comfort. It is apparent to people on the floor that they are seen as less valuable when working in poor air quality conditions. The office should not be a comfortable temperature while the floor is cold during the winter or hot during the summer. The investment of thermal comfort does more than meet a code standard, it signals to your employees that their company cares for them. 

The pandemic brought with it many challenges. One of which being the fact that office workers gained the ability to work from home while those on the floor were still required to be on campus. We realize that the ability to work from home is not going away. However, through continuous improvement, we are striving to find a solution that will bring equality to both sides. 

Breaking down the wall between the office and floor is certainly not a task that can be completed overnight. Rather than being one large change, it comes with small changes or removing of “bricks”. For a healthy culture to exist, it must be unified. Finding ways for employees to dress and think the same are great ways to ensure that everyone feels appreciated and on the same playing field. The benefits of overcoming the challenges are quickly apparent as it improves moral, recruitment, and retention. Help create an awesome workplace by joining Cambridge for a morning meeting to see these ideas in action.