Q Squared Pancake Breakfast Meetings

Our Q2 lunch meetings took a different twist (or should I say flip) this time. The Q2 team treated employees to a delicious pancake breakfast featuring plain and blueberry pancakes, bacon, sausage, orange juice, milk and some great locally produced maple syrup (thanks Paul Aikin).

Many good ideas were brought up and discussed at these meetings. A common opportunity for improvement regarding technical training of the operations group was mentioned at all three meetings. The fact that much of the manufacturing equipment PLC controlled new operators do not have the need to make manual adjustments – and thus may not know the intricacies behind the equipment. The technical training (a.k.a. “DMV U”, like PSU or dare I say OSU) would provide greater knowledge to our employees, helping them to have a better in depth understanding of each unit of operation.

Weekly Meetings - Striving to achieve operational excellence

On September 13, 2006 employee meetings were held in the South conference room. The topic of discussion was one of our core Q2 messages; Striving to achieve operational excellence.

These were some of the best meetings I have been to – a lot of good discussions took place. Individuals shared their ideas on what operational excellence means to them. We talked about many examples of operational excellence. Suggestions for continual improvement were made – and will be followed up.

When everyone works together – great things happen!

Q2 ... Pass it on

We all have to work together in order to succeed. We have to rely on our co-workers to do the best they can before sending the product down the process stream to the next part of the operation. This idea was brought up during the 1st pancake breakfast meeting. It’s a idea that embodies the Q2 attitude. Pay attention to the job you are doing, and realize that your actions affect quality. Not only quality product but quality of life for your co-workers. You can chose to work the Q2 way or the wrong way.

Q2 … pass it on!

Weekly Highlights - 9/12/06

• Breakfast meeting dates have been set.
• The Team reviewed the topics for the weekly training sessions.
• Discussed problems associated with “mixed messages.” An example was mentioned and clarification was given to the production employees on the team.
• Team discussed the first item for training on Wednesday, 9/13/2006. (Striving to achieve operational excellence)
• Follow up: Phones were installed in the two red zone areas to enhance communication and unnecessary exiting from the zones.

Weekly Highlights - 9/5/06

• The communications plan is effectively keeping all employees informed.
• Discussed the need to meet with the “new supervisor training initiative” group to be sure they understand the message they are delivering is a consistent one. Meetings with the Q2 team have been set up.
• The next luncheon meetings with the shifts will actually be “breakfast” meetings.
• Shift training/mentoring meetings will be scheduled for 9/13 (striving to achieve operational excellence), 9/21 (paying attention to our facility and our processes), 9/26 (safety, quality, efficiencies), 10/4 (knowing that our actions influence quality).
• BLT members and others are encouraged to walk through the facility when in town. This is well received by all employees.

Striving to achieve operational excellence.

This is one of our core Q2 objectives. What does it really mean?
In order to secure our continued success DMV has to maintain its production efficiencies and continually improve. How will we accomplish this? By using our resources (people, processes, equipment, systems) in such a way as to consistently produce top quality products the first time, every time. Who is involved? Everyone. Everyone needs to know how to do their job – then have the pride and determination to do it right – every time. Everyone needs to look at their jobs, (the work they do, the equipment & systems they use on a daily basis) for Ideas for improvement. These improvement ideas are necessary to achieve operational excellence.

Back in business!

After a short Hiatus were back in business. Meetings were held with all employees on August 9, 2006. We talked about our monitoring activities to ensure a smooth start-up. With systems and hardware all in check, we focused our meeting on getting our “software” (people) back in shape.

Back in business means back to basics.
Requirements for GMP’s, House rules and hygiene zones were discussed. Everyone knows what is required of them.

Back to basics means back to Q-Squared.
Weekly / bi-weekly meetings have been scheduled for all employees. These are necessary meetings and are designed to make sure everyone is on the same page – focusing on Q2; Living, breathing, and being quality. Choices shall be made based upon our core priorities; Safety (people & product), Quality and Efficiency. (and in that order!)

Back to Q-squared means back TO business!

Thanks!

I just want to say thank you to everyone who turned the devastation of the June flood into our new and improved production facility. Not just the repairs and improvements to the building, but for working together and uniting under such a huge challenge. The team work and spirit of all involved was so gratifying. Seeing this I know we can achieve any objective we set our (collective) minds to. The hard work done by DMV’s dedicated employees truly became the “silver lining of this cloud”.

Quarter 2 Environmental Monitoring Results

No Salmonella detected in any sample / site. Site Y10, the barn cleaner under the drip pan met the alert level for enterobacteriacae. The site was cleaned to prevent any cross contamination.

Five samples met an action level for enterobacteriaceae. (Y10, the barn cleaner under the drip pan; Y3,Drain in V-bottom mix vat room; R1, Sifter screen over air hole of tower drier; R3, Drain in tower drier bag room; and R8,Floor in to tower bag room leading to tower vestibule).

Two sites met the action level for yeast and mold. (GR3, Floor in front of roll up screen door in dirty side of maintenance shop; and GR1, Floor in warehouse by door into production near the mix vats).

Two sites also failed for Standard Plate Count. (R14, Metal tube leading to each arm of the V-bottom bagger; and R4, Black belt that tightens bags around diaphragm in tower drier).

One site failed for E.coli (Y10, the barn cleaner under the drip pan).

All action level sites were cleaned and then re-sampled the following week.

A hygiene investigation was opened because E.coli is found in site Y10. Corrective action is pending as the investigation remains open at this time.

Corrective action. As a result of previous hygiene investigation a corrective action was taken for site R4, Black belt that tightens bags around diaphragm in tower drier. This hygiene investigation led to the purchase of 6 new black belts. Now black belts are switched out for cleaning, thus allowing ample time for drying before use. This change as been recorded in the tower bagging procedure and is now SOP.

Our Actions Influence Quality

Stephen Paolicelli spoke at the July 6th Luncheon and stressed that the actions taken now, during the clean up will have a big impact on the quality of the products when we start producing them again. Employees will need to pay attention to the processes to ensure that safe, quality products are being made for our customers once production resumes. We also need to be vigilant with our prerequisite programs (environmental monitoring, pest control, cleaning and sanitation, etc.)

Breathe, Live, Be Quality

Tasty treats were handed out to all employees at the July 6th Q2 luncheon. Special blue & white MM’s with three different quality messages were given to all in attendance.

We wanted to ensure everyone is thinking about Q2 even at this challenging time. The messages printed on the MM’s were: Breathe Quality, Live Quality, and Be Quality. The messages were originally meant to be sweet reminders, but at this time Breathe Quality, Live Quality, and Be Quality seem to be more of a challenge – a challenge we are ready to face.

All company Q2 Luncheon

The 1st & 2nd shifts BBQ2 Luncheons took place on July 6, 2006. However, all DMV employees (all third shifts and employees from the North building and all management) attended. The atmosphere was casual as we had lunch under outside tents. During lunch, employees enjoyed delicious Italian food as they listened to comments made by Steve Braun, Gary Casterlin and Stephen Paolicelli.

Steve Braun began by thanking everyone in attendance for working hard as we begin the process of cleaning up the plant. The recent floods caused damage to both the interior and exterior of the Delhi manufacturing facility. A lot of work has been done, however much more is still needed.

Steve also spoke about what is needed before we can restart production: the clean-up needs to be completed, the facility sanitized, motors to be repaired and parts of the facility and offices need reconstruction. We need to keep Q2 in front of us as we repair the facility and get ready to restart production.

Gary talked about paying attention to our facility as we make repairs to its structure. We have a clean slate, and everything that comes back into the plant must have a purpose and a home.

3rd Shift Q2 BBQ-Squared

Steaks were sizzling on the grill in the wee hours of Tuesday June 27, 2006 morning. Plant and Quality management were on site cooking for the 3rd shift employees – barbeque-style.

The group discussed the November audit and our need to pay special attention to how our actions affect product quality. Each employee must be able to communicate their important role within the company.

Tell us whats on yoru mind

Q2 Luncheon Schedule

Informal lunch meetings have been set up on the different production shifts. These luncheons are designed to foster open and frank discussions about raising quality to the next level. Luncheons will be held on:

• 3rd Shift - June 27 - 3 a.m. - BBQ – weather permitting
• 1st Shift - July 6th - Noon - BBQ - weather permitting
• 2nd Shift - July 6th - 7 p.m. - BBQ - weather permitting
• 3rd Shift - July 19 - 3 a.m.
• 2nd Shift - July 21 - 7 p.m.

How'd everybody do?

Double Jeopardy

Eight of the nine Q2 Jeopardy teams went for broke, and bet all they had, on the final jeopardy question (and most of them ended up broke!) However 3 teams were able to come up with the correct final question. The maintenance team had the most money going into final jeopardy and was able to doubled their money. They ended with an impressive 9,200. The team will share the grand prize and split $500.00 worth of gift cards.

Weekly Highlights - 6/20/06

∙ Q2 Luncheons – schedule for the next 5 luncheons have been set. Schedule will be posted to the E-board.
∙ Ideal Posters have arrived and will be hung throughout the plant (and labs)
∙ Everyone is reminded to continue communicating to the entire organization, including one employee at a time.
∙ Discussed ways to show how we are doing with regard to awareness and commitment “Thermometer” with increasing level was talked about as being the best way to show our current level and also to show improvement.
∙ Shift meetings will start the week of 6/19 and continue through next week.
∙ The Fraser 2006 Q2 audit is scheduled for Monday, November 13, 2006

Q2 Team Jeopardy Winners

It came down to the wire. With the final team putting all their money on the final jeopardy question. Q.”Two 2 of the 3 core Q2 messages (found on the laminated card and on your paychecks.)”


See next article for contest statistics.

3rs Shift Luncheon Scheduled

Our second Q2 luncheon is scheduled for 3:00 am on June 27th. I can't wait to see you and chow-down in the pitch black of the pre dawn day. Lets discuss what's going on with the project, the improvements made to the plant (even talk about the Jeopardy winners), what else is needed and ideas to ensure our plant is fit for the future.

What can you do to raise quality to the next level?

The first Q-Cards were sent to our employees last week. A lot of improvements have been made and more to come. A personal commitment to these improvement initiatives is crucial to the continued success of our company. Everything depends on our employees.

What are you personally going to do to raise quality to the next level?

Weekly Highlights - 6/06/06

∙ Q-Cards (cards asking a specific Q2 related question) were handed over to Ken. He will in turn meet with operators and hand out. This employee answers will give us good feed back and help us assess our current state of readiness.
∙ Air locks are ready to be used. Training took place on 6/12/06, and we become SOP June 19th.
∙ Light weight over coats are being sourced, to replace the heavier tyvex suits now being used when blending products.
∙ Additional employee meetings will be scheduled
∙ Plant air improvements are almost complete. Waiting on REA to install additional power to the plant. (expected by 1st or 2nd week in July – Just in time!)
∙ Batch cleaning record does include verification of cleaning of environment (such as walls, floors and overhead pipes ,etc.)

First Round of Internal Q2 Audits

All four sections of the facility have been audited by internal Q2 Auditors. While the scores for each section are quite low, the audits give us valuable information on areas that need to be improved.

Every 3 weeks two internal auditors inspect a section (1/4) of the facility. This is in accordance to our audit procedure QAPR052. The complete facility is inspected each quarter. Areas for improvement are noted, and corrective action plans are set. Follow up on corrective actions are made the next time the area is inspected.

What can you do? Your actions can have a big impact on these audits. Housekeeping and GMP's are a big part of the inspection. Please keep your work areas clean. Also you can make your supervisor aware of any problems that you see - either to the physical structure or to a process or a way of working that can be improved (safer, better quality, or more efficient).

You do make a difference and remember "Everything depends on our employees".

E Board now on your Desktop

Now you can keep up with latest E-Board postings right from your computer desk top. The E- board can be accessed via the Fraser IntraNet. Click on Q-Squared and then click the E-board link.

Q-Squared Team Jeopardy

Get those buzzers ready, Jeopardy is coming to Fraser! The team contest will begin the week of January 19t, 2006.

Teams consisting of about 10 employees will be testing their Q-Squared knowledge and completing for the grand prize of $500.00.

Each employee is required to answer at least 2 of the 25 questions. Points will be awarded for each correct answer.

Teams can bet all earned points for the final jeopardy question. The team with the highest points after final jeopardy will be the winner.

Operations will have 4 teams (first shift employees will make 2 teams, then one team for each 2nd and 3rd shifts.) Everyone else will be put into teams.