Program subject to change

Wednesday, May 14  • Thursday, May 15  • Friday, May 16

Wednesday, May 14, 2008

7:00 - 8:00 am Continental Breakfast

8:00 - 8:15 am Conference Opening & Welcome and Awards Presentation

8:15 - 9:00 am Keynote Presentation (General Session)
Dr. M. Ray Perryman, Perryman Group

Dr. Perryman is Founder and President of The Perryman Group (TPG), an economic and financial analysis firm headquartered in Waco, Texas. He is widely regarded as one of the world’s most influential and innovative economists.  Dr. Perryman will take a look at the US economy and discuss its impacts and expansion possibilities for the future.

9:00 - 12:00 pm Concurrent Sessions:

Track 1: Electrocoat Basics
Bulk E-Coating of Parts on a Conveyor Belt
James Gleason, George Koch Sons, LLC

Finishing parts usually involves suspending them from a rack or loading them into a basket or barrel.  The labor costs associated with loading, unloading, and maintaining racks or other containers can be substantial.  These costs can be avoided by electrocoating bulk parts on a conveyor belt.  Recent work has demonstrated the feasibility of this process. This session will discuss how a bulk / belt electrocoat operation differs from a traditional electrocoating operation and will describe the best applications for this process and the process limitations.

Material Handling - Monorail/Power and Free Conveyors and Hanger and Rack Considerations
Ed Diekmann, George Koch Sons, LLC

This session will focus on the various considerations for designing a conveying system for handling parts through a paint shop.  It will describe the advantages and disadvantages of powered monorail conveyors and overhead Power and Free conveyors.  The load capabilities of each type of conveyor and a brief description of maintenance procedures will be presented, as will the design of racks to handle the product.  The design of racks includes surface area of parts, weight of parts, grounding of parts and spacing of parts on a rack.

Material Handling - Programmed Hoist and Square Transfer Indexing Systems
Ted Duda, Therma-Tron-X, Inc.

No one system type is superior in all electrocoating operations. Square transfer indexing systems can, in many cases, offer the electrocoater several advantages in terms of floor space usage, tank charge costs, capital and operational expenditures, and pretreatment options. Programmed hoists may be cost effective options for the painting of large, heavy parts with low throughput requirements. An examination will be made of considerations that match equipment capabilities with product, process and facility demands.  Best applications for use of these types of systems will also be discussed.

Track 2: Process Improvements
Current Density Control of E-Coat
Craig Henry and John Bougneit, JP Tech

This discussion will focus on optimizing your throwpower by utilizing efficient density control.  We will take a look at voltage versus throwpower and the effects on different e-coat system types such as square transfer, monorail and rectifiers.  Potential savings by optimizing your throwpower will conclude the session.

Membrane Filtration for Recycling Alkaline Degreaser
Eric Legatski, CelTech

A recent application of membrane filtration to alkaline degreaser will be discussed.  The process involves the ultrafiltration of the alkaline degreaser to separate the oil and soil from the cleaner.  The purified cleaner is recycled to the washer system and the oil and soil are concentrated in a working tank.  By continuously filtering the alkaline degreaser stage, the oil and solids levels in the process are always low, increasing the efficiency of the cleaning stage and consequently the entire system.

Dirt Identification and Elimination
Joe Subda, DuPont Performance Coatings

Dirt - everybody has it, nobody wants it!  Small shops with two people up to large shops with a hundred people have dirt in their coatings.  With an infinite number of sources and a variety of shapes and sizes, dirt in paint is hard to control and nearly impossible to eliminate.  Controlling and eliminating dirt can only be accomplished through a comprehensive dirt program. Learn what such a program is comprised of and how to apply it to your shop in an easy-to-follow, step by step format.

Iron Removal - Prolonging and Improving the Operation of Pickle Baths
Gordon Johnson, Therma-Tron-X, Inc.

Acid pickle baths are becoming more and more prevalent as a component of a complete pretreatment regimen for many steel products, especially when welding scale or surface rust is present. This session will determine the conditions under which a pickling stage is warranted, analyze design considerations for adding a pickle bath to a pretreatment system, examine the iron removal process and equipment required to maintain the pickle, and resolve waste disposal requirements for the operation.

Question & Answer Panel - All Speakers from this session participate.

10:25 - 10:30 am Break

Track 1: Electrocoat Basics (cont'd)
Pretreatment
Bruce Goodreau , Henkel Corporation

Metal pretreatment processes have been used in manufacturing of goods for nearly a century. Metal pretreatment is a key part of preparing surfaces to be coated using electrocoat paints. The processes involve multiple steps including cleaning, pickling, surface conditioning, conversion coating, and post treatment.    Iron phosphate and zinc phosphate are the two most common processes used in metal pretreatment.  The basic chemistry of these processes will be reviewed with a focus on paint adhesion and corrosion protection.

Basics of Electrocoat
Robert Doty, BASF Corporation

Electrocoat is an immersion liquid coating applied solely by electricity.  This technology has existed for over 30 years with the primary purpose of providing corrosion protection for a variety of applications in several industries.  Included in this basics discussion are:

• The performance and economical benefits of electrocoat
• The history of electrocoat
• How electrocoat works
• The components and parameters of the electrocoat bath
• An overview of the electrocoat process

Curing
Tom Neeley, George Koch Sons, LLC

Cure ovens are an integral part of the Electrocoat process. This presentation explains the basic process considerations that drive the design of an E-coat oven process to cure the product. Discussions are included on how to evaluate an oven's process performance and where operating dollars are being spent.

Industrial Waste Water Treatment for Metal Finishing Industrial Processes: Design and Operation Considerations
Mark Zeilbeck, J.Mark Systems

The purpose of purchasing and operating an industrial waste water treatment system is to comply with federal, state and local effluent discharge requirements for the process waste water solutions.  This session will discuss the basic need to identify and define the waste water solutions, their chemical characteristics and concentration levels, the methods available for lowering their concentration levels to compliance standards, and the skill level to successfully operate these systems.  Additional items of discussion will include waste minimization, monitoring of key system functions, water reclaim techniques and the need for investing in operator training.

Track 2: Advancements in Electrocoating Processes
Advancements in Electrocoat Bulk Coating Chemistries
Jill Tersteeg, The Valspar Corporation

The finishing industry has been challenged with successfully coating small parts - specifically balancing the ability to get full coverage in a cost effective manner.  Over the past 10 years, the electrocoat industry has found a method of coating small parts in a drum or barrel rolling process. This technology has been successfully commercialized in many specialty market segments, but has not become the standard for many small parts market segments because the process can lead to excessive “touch marks” and, therefore, premature corrosion failure.  These problems can be dramatically improved through resin formulation technique, paint product formulation technique, and changes in the coating and curing process.  This presentation will explore some of the formulation techniques and process changes that maximize touch mark resistance and, therefore, the properties that can be developed with the bulk coating process.

Electrocoating in Five Colors
Chad Andreae and Bradley Andreae, Therma-Tron-X, Inc.

Multiple color use in the e-coat process can be problematic because of the need for paint segregation and change-over. This session describes the design and operation of a system that e-coats fasteners in baskets in any one of five colors (with a future option for a sixth color). Consideration will be given to system layout, concerns about paint contamination, material handling automation, load tracking, paint handling and waste disposal.

Expanded Uses for High Edge Protective Electrocoat
Jonathan Love, PPG Industries

The concept of improved edge protection in electrocoat dates back well over 15 years.  As a deposited electrocoat film heats up, but before it cures, its own surface tension has a tendency to pull the coating away from the sharp edges.  Once cure temperatures are attained and crosslinking occurs, the result can be exposed metal edges with a very thin or no protective coating.  Advanced formulation electrocoatings that prevent this problem have found widespread application as ideal single coat finishes for automotive chassis components.  The electrocoat marketplace is now beginning to realize the benefits of maximum edge protective coatings for a broader range of industrial and automotive components.

Electrocoat Primers for the Aerospace Industry
Robin Peffer, PPG Industries

In February 2006 OSHA announced that the PEL (permissible exposure limit) for hexavalent chrome would be significantly reduced. While engineering solutions are required for the Aerospace Industry as an initial means to reduce worker exposure to chrome, they are often not feasible and may require additional facial protective equipment. The electrocoat process is a viable alternative coating method for the Aerospace Industry. It offers multiple advantages including full automation and >98% paint utilization which leads to significant reduction in worker exposure, uniform film build all over the part which correlates to weight reduction even on complex part geometries, and the ability to increase productivity with minimal labor. By comparison, the electrocoat process enables a reduction in the chrome level of the dry film by 80% or more, resulting in lower overall worker exposure. As the Aerospace OEM’s and subcontractors move to comply with the new limits and turn to more environmentally friendly products, the electrocoat process stands ready to deliver.

Question & Answer Panel - All Speakers from this session participate.

12:00 - 1:00 pm Group Luncheon

1:00 pm - Exhibit Rooms Open for Company Product Information
Exhibit rooms will be open with company personnel available for product review, informational interaction and question and answer.  Attendees have a unique opportunity to discuss specific needs or concerns in the privacy of individual vendor rooms.

1:00 - 1:50 pm Workshops
Workshop A - Troubleshooting: Paint Defects
Jim Gezo, PPG Industries

This presentation will present some of the more common defects associated with the electrocoat finishing process.  The majority of these defects are typically “self inflicted” and not truly associated with the finishing process.  We will analyze defects, their common causes, usual corrective actions, and long term plans that can insure consistent, defect free production.    

Workshop B - Lean Aspects of E-Coat
Brett Hyndman, Doug McPheron, and Gary Orosz, PPG Industries

We all have been hearing the words “Lean”, “Lean Manufacturing”, “Value”, “Value Stream”, “Process Flow”, “Pull”, “Perfection”, “Consensus”, “Continuous Improvement” and “Waste,” to name just a few.  Are these just the latest buzz words, or are these real principles that can be applied to your operation?  In today’s economic climate, we all need to look at ways that we can provide quality parts that meet the customer’s requirements, on time, every time while trying to become or remain the low cost producer.  In this interactive workshop we discuss some of the principles of Lean Manufacturing in general and as it applies to Electrocoat systems.  Active discussion and thought sharing is strongly encouraged as we examine Lean Manufacturing concepts.

Workshop C - Exploring Alternative Outsourcing Models for Electrocoating Services
Tim Klopfenstein, MetoKote Corporation

Coating application is often considered a “necessary evil” for manufacturers and suppliers of components in any industry.  Traditionally, manufacturers have been forced to either install their own in-house coating equipment or ship parts to the nearest capable job shop.  This workshop will analyze an alternative model for outsourcing electrocoating services whereby an external system integrator designs, builds, installs and operates a coating system inside the customer’s facility.  Considerations for this decision making process will be identified and advantages, disadvantages, and potential risks of the model will be presented. With proper planning and knowledge, the risks can be minimized or eliminated to ensure the successful delivery of the model.

2:00 - 2:50 pm Workshops
Workshop A - Repeat from 1:00 pm

Workshop B - Repeat from 1:00 pm

Workshop C - Best Practices for Operating Membrane Electrode Systems and UF Systems
Frederick Hess, UFS Corporation

Regardless of the manufacturer of your membrane electrodes (ME) system and ultrafilter (UF) system, this workshop will provide the “best practices” to keep your ME and UF systems operating efficiently for a more consistent finish, with cost savings being the benefit to e-coaters.  Basic operating parameters, equipment checklists and troubleshooting guides will be presented and discussed.  

3:00 - 3:50 pm Workshops
Workshop A - Repeat from 2:00 pm

Workshop B - Repeat from 2:00 pm

Workshop C - Electrocoat Calculator
Joe Subda, DuPont Performance Coatings

Reducing costs while maintaining or improving quality is a common challenge among electrocoaters and can be tricky or impossible if the right information is not known.  A hidden cost might be missed or an area with a higher return could be overlooked.  This workshop will discuss how to calculate and determine costs that are associated with an electrocoat system.  Calculations discussed range from energy consumption to paint usage.  Examples will be presented and discussed.

4:00 pm - Exhibit Rooms Open for Hospitality

Thursday, May 15, 2008

7:30 - 8:15 am Continental Breakfast

8:15 - 9:00 am Keynote Presentation (General Session)
Global Considerations for Electrocoat
Dan Ruble , PPG Industries

All of us are aware of the significant economic expansion in Asia over the past decade. New plants and coating systems of all types are starting operation every week. Electrocoat has been used in Asia for many years in the traditional automotive, appliance, and general primer markets and is now expanding into all of the same industries and markets in other areas of the world, like North America and Europe. There is also significant potential for many new markets for e-coat within Asia. The growth of electrocoat in Asia over the past 10 years and its future in this dynamic region of the world will be examined. We hope to share a perspective of the challenges for e-coat's global growth, including language, culture, technology, and environmental issues.

9:00 - 12:00 pm- Concurrent Sessions:

Track 1: Plant Operations
Advancements in Cathodic Acrylic Electrocoat Technology
Cullen McDyre, The Valspar Corporation

Acrylic polymers have been used in the electrocoat industry for many years, starting with anodic technologies that delivered low cost finishes with limited performance properties, and evolving into cathodic technologies that delivered respectable durability.  However, the promise of cathodic acrylic technology – specifically a single coat finish that delivers full coverage and superior performance properties – has not been fully realized due to the gap in performance between primer / topcoat systems and a single coat finish.  Recent advancements in acrylic resin technology as well as formulation technique have narrowed this gap considerably and increased the practical utility of this coating option.  This presentation will explore these advancements, discuss the performance properties that are now attainable, and model the potential cost savings available to finishing operations that could switch to a single coat finish.

Custom Masking for E-coat
Keith Bice, Hi-Tech Flexible Products

Expense or investment?  Necessary evil or competitive advantage?  In this session we will discuss what custom masking is and its purpose for manufacturers.   Our focus will be the many advantages of custom masking as well as associated costs.

Ultrafiltration Technology for Pretreatment and E-coat Paint
Gerry Lachut, The Hilliard Corporation

A new, dense pack ceramic membrane cross flow technology has demonstrated a new way to efficiently maintain pretreatment baths as well as E-Coat paint baths.  The ceramic membrane removes oils, greases and other contaminants.  Continuous filtration of pretreatment baths with the Ceramic Filter consistently maintains the quality of the bath and product, and extends bath life by reducing new chemical purchases, disposals, energy and labor costs.  The new technology can operate at temperatures up to 200 degrees F and does not remove measurable amounts of soaps and other bath additives. It has proven to increase filtration performance in E-coat baths as well.  The membrane achieves a decreased fouling rate over other membrane filters.  The ceramic can be aggressively cleaned, recovering more of the flux rate after fouling.  The enhanced performance results in cost savings in labor and filter changes, and production of a higher quality part improves process control.

The Electrocoating/Top Coating of Large Enclosures
Blake Eckard , Altec Industries, Inc.

Because it is an immersion process, the electrocoating of large enclosures can present various difficulties.  Among them are concerns regarding air entrapment, thorough draining, carryout and bath contamination, striping and low mil build.  This session will examine how and why a manufacturer of truck bodies added e-coat to the finishing operation at its new facility and relate how the design and execution of an electrocoat/liquid spray topcoat paint system addressed the problems listed above, among others.

Track 2: Going Green-The Environmental Impact of Electrocoating
Reduction of Environmental Impact with the MRS™
Steven Buday, Plymouth Technology

Plymouth Technology has developed a new, environmentally sound approach to the treatment of electrocoat waste streams.  Plymouth’s Metal Removal System™ reduces environmental impact through lower chemical usage, sludge generation, and lower residual metals in discharge effluent.  Electrocoat operations utilizing Plymouth’s MRS™ were able to achieve dramatically lower metals numbers in effluent waters (allowing electrocoaters to operate within tight discharge limitations), reduce or eliminate conventional wastewater treatment chemicals, drastically reduce the amount of solid waste generated (most sites see a sludge reduction of greater than 75%), readily reuse more than 50% of wastewater, and significantly reduce manual labor requirements.  Plymouth Technology field data detailing successful e-coat applications will be reviewed.

Bacteria Control in Electrocoat DI and RO Water Systems
Charles Orr, BASF Corporation

Bacteria growth in electrocoat systems has become a challenging dilemma in recent years.  Paint and pretreatment systems have become more environmentally friendly, which also makes them a more favorable bacteria haven.  Therefore, more scrutiny must be placed on the electrocoat system surroundings to control the propagation of bacteria.  Within the electrocoat system, there is no single bacteria source risk greater than DI (deionized) or RO (reverse osmosis) water, based on the high quantities of a very bacteria-friendly environment that are added to these systems on a daily basis.  DI and RO water each offer unique challenges for bacterial control in electrocoating systems.  RO water is sterile as supplied from the membranes, so the strategy to control bacteria can be different from DI water, which typically has 10-100 colonies/ml in its virgin stream.  Therefore, distinctive bacterial control methods must be explored to either kill high quantities of bacteria or inhibit initial growth.  Some of these strategies include biocide, hydrogen peroxide, UV light and ozone as it applies to bacterial control in DI/RO water in holding tanks, electrocoat rinses and the final rinses of the pretreatment system.

Reverse Osmosis for Electrocoat Paint Ultrafiltrate at an Automotive Assembly Plant
Dr. Mark Rizzone, Koch Membrane Systems

Ultrafiltration is the traditional membrane technology used for electrocoat paint.  The application is well known and widely practiced.  Less known and less practiced is reverse osmosis for ultrafilter permeate from an electrocoat process.  Benefits can include less deionized water consumption, increased paint solids recovery, higher quality closed loop rinsing, and less paint solids to waste treatment.  All of these can result in cost savings to the electrocoat end user.  The application of reverse osmosis to electrocoat paint ultrafiltrate is described.  The performance of the reverse osmosis membrane will vary depending on the type used.  Recent data from one type of reverse osmosis membrane has shown relatively stable performance. Case histories are presented for two automotive assembly plants.    

Question & Answer Panel - All Speakers from this session participate.

10:25 - 10:30 am Break

Track 1: System Management
Turn Off the Heat
Tom Scherr and Scott Lassa, PPG Industries

Global warming, global outsourcing, global competitiveness, and global raw material demand dominate the headlines.  The flattening of the world relative to communications, physical mobility, and reduced trade barriers has enabled companies to reach far beyond their borders to grow revenue and profits.  Competition requires fair pricing and high quality while maximizing profits.  Global demand for natural resources increases costs, eroding competitiveness and profitability.  Reducing energy dependence offers one option for cost savings.  Since 2002, the price of natural gas has increased from $3/MBTU to about $8/MBTU, a 267% increase.  Moreover, the price of natural gas spiked at $15/MBTU in December of 2005, a 500% increase over prices just three years previous.  Energy cost savings can be accomplished by hedging the market, installing more energy efficient equipment, insulating buildings, or implementing conservation plans.  Another option involves reducing the heating requirements of the metal finishing system.  A move to low-temperature processing in your pretreatment line can yield significant annual savings.  This can be accomplished by switching to a new generation of ambient pretreatment technologies.

Efficient Electrocoat Tank Operation
Joe Subda, DuPont Performance Coatings

Electrocoating is a very efficient process.  It’s automated, has high transfer efficiency and a rinse system to reclaim lost paint; what could be better?  Well, things can be better, but change requires planning and training.  The efficiency of an electrocoat process can be improved in many ways such as changing paints, installing new equipment, and changing racking, to name a few.  But the best or first place to start improving the efficiency is with Statistical Process Control.  Learn what SPC is and how to apply it to your electrocoat system in an easy to follow, step-by-step format.

Automated Monitoring of your E-Coat System
David Wolf and Phil Hopper, Hayes Lemmerz, Inc.

At Hayes Lemmerz in Sedalia, Missouri, a tier 1 automotive supplier of steel wheels, there are numerous critical parameters in our ecoat systems that required a technician to monitor.  We wanted to install, at minimal cost, a computerized system to monitor and record key process parameters and alert the technician when any of them fell outside of the specifications.  We found the answer to our problem at the 2006 Electrocoat Conference.  John Bougneit and Craig Henry from JP Tech presented a system that appeared to be a good solution.  We took their idea and developed it into a full scale Human Machine Interface – System Control and Data Acquisition system (HMI-SCADA™).  Using off the shelf software and some very inexpensive input / output devices, we created a system to automatically monitor the temperature, pressures, tank levels, and pH of our ecoat systems for less than $10,000.  Ours is a success story of taking a great theoretical idea and expanding it into a full scale practical application that has generated immediate cost savings and improved quality.

Track 2: Quality Control Requirements
Quality Assurance/Quality Control - The Difference Is?
Kreg Kukor, Vwebpartners LLC

This course will discuss Quality Control and Quality Assurance, what each are, what each are not and why a quality assurance program is important to your manufacturing process.

Establishing Quality Principles
Kreg Kukor, Vwebpartners LLC

This session continues the quality assurance discussion from defining quality assurance principles to touching on implementation of quality assurance principles into your manufacturing environment.

Introduction to Performance Testing
William Lemons , PPG Industries

Are you confused by the performance testing requirements for your electrocoat parts?  Would you like to know the difference between a specification and a process standard?  Have you ever wondered why the various OEM’s have different requirements for the same test?  Are you interested in learning about test methods?  If your answer to these questions is yes, this presentation is for you.  Performance testing consists of a variety of physical, visual and corrosive tests, and we will teach you the basics!

Question & Answer Panel - All Speakers from this session participate.

12:00 - 1:00 pm Group Luncheon

1:00 - 1:50 pm Workshops
Workshop A - Troubleshooting - Pretreatment
Terry Giles, Henkel Corporation

The base for good adhesion and corrosion performance is the synergism between the substrate, pretreatment and electrocoat system. If the process is done correctly the first time, the performance of the system is not compromised. In this interactive workshop specific pretreatment problems will be examined, discussed and reviewed as to how pretreatment can impact performance. Real life examples and solutions to specific pretreatment problems will be examined.

Workshop B - Workplace Safety
Johnny Trammell and Jay King, Indiana Department of Labor - INSAFE Division

Learn to identify and correct hazards that are most often cited by OSHA. The top ten most cited standards in 2006 will be identified and discussed from both a safety and health perspective from 29 CFR 1910. Additional topics include ways to ensure compliance before an OSHA inspection and ways to improve written safety and health programs.

Workshop C - Current and Future Prospects for Manufacturing in the USA
Jeff Oravitz, MetoKote Corporation

Manufacturing in the United States has historically contributed mightily to GDP, and has also provided a large component of the overall workforce and business opportunities.  From the early Industrial Revolution through the dawning of the 21st century, American manufacturing has emerged, developed, grown, and shifted as a result of changes in the global economic environment. 

As we near the end of the first decade of a new century, many major influences are shaping the prospects for manufacturing in the United States.  Some of these influences include: 

            The upcoming American Presidential election
            Debate regarding the impact of free trade agreements
            Continued globalization in search of the low cost basis
            Access to a skilled workforce
            The declining value of the US Dollar 

We will explore these topics as they pertain to the current and future prospects for manufacturing in the United States.  Participants should be prepared to share their own insights, experiences, and ideas to facilitate discussion during this session.

2:00 - 2:50 pm Workshops
Workshop A - Repeat from 1:00 pm

Workshop B - Repeat from 1:00 pm

Workshop C - Best Practices in Part Hanging and Masking for Electrocoating
Scott Rempala, Mighty Hook, Inc.

A basic overview of contemporary hanging and masking techniques and technologies for electrocoating will be presented.  Hanging density to get the most out of your coating operation and hanging methods to insure proper cleaning, drainage and positioning of parts are among the topics addressed in this workshop.   New products that address common hanging and masking problems will be discussed.

3:00 - 3:50 pm Workshops
Workshop A - Repeat from 1:00 pm

Workshop B - Repeat from 1:00 pm

Workshop C - Branding Your Company and its Message
Jean Marie Saidler, JMS Consultants

Branding is an important source of competitive advantage. Strategic branding is critical in order to effectively communicate the benefits of your product and services within tight budget constraints.  Branding can play an important role in industrial purchase decisions. Today, like it or not, manufacturers and distributors need to maintain a strong image. Instilling confidence in your stability is especially important in a struggling economy, when your own customers are re-evaluating their budgets and their spending even with their most valued suppliers.  This workshop will focus on how to brand your company and technology through corporate positioning, strategic planning and proper design implementation.  Learn to identify cost effective ways to leverage your company image to a higher level of awareness. 

1:00 pm - Exhibit Rooms Open for Company Product Information
Exhibit rooms will be open with company personnel available for product review, informational interaction and question and answer. Attendees have a unique opportunity to discuss specific needs or concerns in the privacy of individual vendor rooms.

4:00 pm - Exhibit Rooms Open for Hospitality

Friday, May 16, 2008

7:30 - 8:30 am Continental Breakfast

8:30 - 9:30 am Keynote Presentation (General Session)
Matt Kirchner, American Finishing Resources, LLC

Matt is presently the Chief Executive Officer of American Finishing Resources, LLC. He serves on the U.S Coast Guard’s AIM Selection Committee, the Operation Freedom Steering Committee, and on the Corporate Board of the Milwaukee School of Engineering.  He is the past-President of the Milwaukee Branch of the American Electroplaters and Surface Finishers Society and is the author of “Never Finished” a regular management column appearing in Products Finishing magazine. In 2004, Kirchner was named to the Business Journal’s “40 under Forty”, honoring leaders under 40 years of age who have succeeded in business and given back to the community.

The Toughest “S” – Sustaining Change in a Lean Surface Finishing Culture

Lean is implemented, bottlenecks and constraints removed, production balanced, Kanban quantities set, the waste is gone and progress is readily evident on the financial statements.  Management throws a party to celebrate victory and all is right in the Surface Finisher’s world…..For Now. Amazing, however, the number of manufacturers who stop here and move from Lean onto the next flavor of the month.  Six months later all of the hard-fought gains and cost reductions that were achieved have been crowded out by the pre-Lean inefficient habits that have worked their way back into the organization.  The benefits of Lean are only as effective as the organization’s ability to sustain them long after the novelty and excitement present when they were intiated has passed.

In his thought provoking, entertaining and informative style, Industry CEO, Product’s Finishing columnist and Management Consultant Matt Kirchner explores the most critical steps to ensuring that the benefits brought by the implementation of a lean culture are still enjoyed and being built upon years into the future.

9:30 - 10:30 am Expert Panel Discussion

10:30 - 11:30 am Audience Survey/Game Show

11:30 - 12:00 Noon Closing Remarks & Conference Adjournment