{DDEES, LLC & Full Circle Quality

Don Dees CEO & PresidentCell: +1 (616) 902-2894ddeeshome@aol.com

Web Site: DDEESLLC.com&Web Site: FULLCIRCLEQUALITY.com

Don DeesMobile: +1 (616) 902-2894 Email: ddeeshome@aol.com Web Site: DDEESLLC.comWeb Site: FULLCIRCLEQUALITY.com

Full Circle Quality performs the following: 

1. Consulting Services Coach to implement & sustain Quality SystemsLEAN Manufacturing Processes Problem Solving General Management/Leadership ProcessesStamping, Welding, Plastic Injection Molding, Painting, AssemblyMaterial Handling & Logistics

2. Inspection/Sorting and Containment Sorting/Containment Incoming Inspection Vehicle InspectionStatistical Sampling Root Cause Analysis General Rework of parts

3. Assistance in Hiring Technical Experts Hire North Americans with Specific Skills to Help in China or in NA

4. TrainingQuality SystemsLEAN Manufacturing Problem SolvingLeadership Technical Training

We have over thirty (30) Professional Team Members with Manufacturing Experience of over 25 years per person.

We have a team of Technical Experts (Process Engineers) with years of experience with Automotive OEM’s, who can help you solve any of your Stamping, Welding, Plastic Injection Molding, and Painting issues. We specialize in Quality and LEAN.

We also perform Third Party Inspection & Repair Services.

We have People who can Train your Team on all of the subjects listed above.

Don Dees

•Vice President of Quality•Vice President of Manufacturing $1 Billion savings per year from

improvements in warranty Instituted Commonization of

Vehicle Sub-Systems and Components; thus saving DaimlerChrysler an additional $2 Billion per year.

• Top American Leader Developed the TPS

Training Materials & Trained the TM’s

•CEO & President Private Equity Three (3) Portfolio

Companies Ten (10) Manufacturing

Plants $400M in Sales Revenue Annual ongoing cost

savings of over $17M per year $20M of cash generated

from reducing inventory levels

New Product & Markets

Proven Lean Operations & Implementation Experience: (Trained from the “floor up”) Trained by Toyota in Japan (Best Japanese TPS trainers in the

World) not by book, theory, or consultants. Applied Lean Knowledge by starting up New Toyota Plant. (1st Year

it won JD Power) Ground up plant launch: Toyota Hiring Process, Developed the TPS

Training & Trained the first 600 TM’s, Launched the Plants(2), Improved NA Suppliers w/TPS

I have implemented these LEAN/TPS tools in OEM’s (GM, DaimlerChrysler & Hyundai), Supplier Companies (BHM Technologies, China), and NON-Automotive Companies (Deere, Cat & China Suppliers); in Both Union & Non Union Environments and in Countries & Cultures across the World.

Proven Ability to Find Talent, Develop Leaders, Teach & Coach, Develop a Great Team, and Get Results Multiple Success Stories in many different Cultures & Countries Experience with aspects of corporate financing & restructuring Successful in New Business Start-ups Successful in Sales & Marketing USP Products Successful in Innovating New Products & New Markets Experience in B2B, B2C, Wholesale, Retail, Dealerships &

Aftermarket

“PROVEN CHANGE AGENT”

•Director of Paint Engineering•Plant Manager•Experience includes: USA & Canada Germany England Japan

•Vice President of Quality & Service Hyundai Quality improved to the top #1 non-luxury vehicle nameplate Started Service Contract Business Started Certified Used Car Program

DDEES, LLCFULL CIRCLE QUALITY,

LLC•CEO & President Consulting Company of

Professionals that assists Chinese and NA Companies

Quality & LEAN Manufacturing Third Party Inspection &

Containment of Suspect Poor Quality Parts

Training Technical Assistance Contract Employees “Headhunter” Assistance

Donald (Don) DeesMobile: +1 (616) 902.2894 Email: ddeeshome@aol.com Web Site: DDEESLLC.comWeb Site: FULLCIRCLEQUALITY.com

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Examples of Improvements made Before & After LEAN Manufacturing

Results! Our clients are obtaining results of between 17 and 35 ROI.In other words, for every dollar spent implementing LEAN, they are saving 17 to 35 times this amount of money the next year.

Example of a Project just completed in China

Results from LEAN Manufacturing Project (8.5 Month Project)Safety• Have now gone over 200 Days in a row without any Safety Accidents in the

Plant(s)

Quality (Customer)• Went from 1,000 PPM’s to Zero PPM’s & Zero QIR’s for six (6) Months in a row• Went for Last Place (#16 in 4/2011) to First Place (#1 in 4/2012) in Suzuki’s

Ranking of Stamping & Welding Suppliers in China• Went from being on the “NOT allowed to Bid on New Work List” (because of past

performance and lack of quality processes) in Q3 of 2011 to “Preferred Supplier List” in April 2012 with Suzuki, Chang An, JCI, LEAR and other Customers.

Quality (Internal)• Went from Checking & Repairing 300% of the parts to 0% Checking & Repairing of

the parts on eight (8) totally different Final Assembly Part Numbers (IP Cross Car Beam, Seats, Steering Column Support Bracket, Radiator Assembly, Engine Tubes, Others)

Delivery• 100% On Time Delivery for six (6) months in a row• Eliminated the need for a Third Party Warehouse for Finished Goods• Eliminated 33% of the Inventory ($4M USD)

Cost• ROI of 17 Times what was spent to Implement LEAN Manufacturing• Saved Manpower, Space, Scrap, Inventory, Needs for new Capital Equipment,

Others

5S & Visual Management

Entrance into the Plant Before LEAN

Entrance into the Plant After LEAN

Entrance into the Plant After LEAN

5s & Visual Mgt. Before LEAN

5s & Visual Mgt. After LEAN

Safety

Before LEANSafety Chain IssueWall needs RepairedWood in the Window

Before LEANParts on FloorHose on Floor100% Inspection & Repair

Parts on

Floor

After LEANSafe Work Heights Safe Standardized Work Practices Zero Inspection & Repair Zero Quality PPM’s to Customer

LEAN Manufacturing Safety Tools (at employee entrance into the plant)

The light is “Green” if there have been no accidents or no near misses during the past two (2) days.

Quality

Before LEANPoor Work Position & Parts on the FloorRepair with a Hammer 100% of the Parts into Correct Shape 100% Inspect & Repair

Bigger Hamme

r

Quality Samples and Gages Before LEAN

Quality Samples & Gages After LEAN

Implemented Error Proofing (Air into Weld Nuts to prevent weld balls getting into the threads)

Delivery

Before LEAN“Pearl Diving” into Big Boxes NO FiFONo Pull System for Material Scheduling

After LEANJITSmall PackagingFiFO“Pull System”

After LEANJITSmall PackagingFiFO“Pull System”

零件 A

Cost

Original Situation had 40 steps in the “Total Process” before LEAN

Original Situation had only 15 steps in the “Total Process” after LEAN

Implemented Cost Reduction by Designing Stackable Rack(s) with Wheels (to move with a tugger instead of a Fork Truck)

People

Communication Board(s) After LEAN