Powertrain Systems engineer named Shainin
‘Rolling Top 5^® Manager of the Year’ at annual
Shainin Symposium

The Annual Shainin Symposium, held on April 8 at the Sheraton in Novi, Mich., drew together problem solvers and leaders to share learning and best practices achieved using Shainin methodologies.  John D. Phillips, Delphi Powertrain Systems senior staff research engineer, Gas Engine Management System (EMS) PBU, was honored as Shainin’s 2007 Rolling Top 5 Manager of the Year.  Phillips was selected globally amongst all Shainin Rolling Top 5 Managers.  The Shainin Executive committee selected him for 2007.

Phillips stated, “The Gas EMS PBU leadership has been very supportive of our Rolling Top 5 process.  Many of our plant managers, chief product engineers and chief manufacturing engineers have earned their Rolling Top 5 Executive certifications, and we are beginning to focus on the next level of our organization.”  He continued, “This has allowed us to solve many difficult technical problems, learn to manage the investigations to lead to the discovery of the root cause of problems quickly, and help our people develop this critical skill.  I was proud to accept this award on behalf of the Delphi team.  It is a personal recognition that would have been impossible to earn without being a part of a high performance team.”

A Rolling Top 5 Manager is recognized as a management sponsor who monitors day-to-day progress on Rolling Top 5 projects, and assists problem solving and problem prevention teams. Requirements for certification include demonstrating successful project and organization structure development, implementation and leveraging using the Rolling Top 5 process.

“I am very proud of John's recognition as Top 5 Manager of the Year,” said Mark Shost, engineering director, Engine Management Systems & Products.  “His hard work to develop a strong I&CIM program within the Gas EMS PBU started four years ago and John's leadership to establish a strong program - including training coordination, use of multiple methodologies and Rolling Top 5 report-outs, all while still actively leading key problem-solving projects himself - has helped change the way we approach product development.”  

Delphi Corporation’s implementation of Shainin’s tools and techniques was evident in both the presentation of awards and case studies.

New Shainin Masters, certified from April 2007 through April 2008, were also recognized globally; seven of thirteen were Delphi’s own:

• Red X^® Master
  1. Jim Tye, Interiors, I&CIM manager
  2. Warren Weingartz, Steering, senior statistical engineer
  3. Clyde Nichols, Powertrain Systems, senior statistical engineer
• Green Y^® Master
  1. Don Bender, Powertrain Systems, staff research engineer
  2. Ed Rivera, Powertrain Systems, staff reliability engineer & GDi system integration
  3. Dean Flower, Steering, Athens site Rolling Top 5 problem solving / problem prevention
  4. Lynne Hrusch, Powertrain Systems, senior statistical engineer

Delphi Powertrain Systems leaders presented two of nine case studies, each demonstrating the application of Shainin strategies and techniques, including:

• Process Innovation and Perfect Launches Using the Green Y Process  Risk ReduXion to Eliminate the Contradiction
  Amy Adams, Delphi Powertrain Systems chief manufacturing engineer, powertrain products
  Increased risk and failed or flawed launches can result from the process innovation for increased product performance and decreased manufacturing costs.  Green Y Process Risk ReduXion techniques have enabled the development, qualification, implementation and duplication of new and innovative processes, while minimizing launch risks. This project demonstrated the use of the Shainin Green Y methodologies to develop process innovation and perfect launches.
  
• Risk Reducing Equipment Procurement
  Pete Bovenzi, Delphi Powertrain Systems chief manufacturing engineer, exhaust systems
  Understanding the key control factors that drive process capability and product performance is critical when developing a new manufacturing process.  This presentation makes a compelling case for proactive risk reduction on new equipment to identify and confirm these critical relationships before machine specifications are finalized.

Richard D. Shainin, Executive Vice President and host for the event, said, “We were delighted with Delphi’s participation at this year’s symposium. The Delphi presenters conveyed a passionate drive to achieve excellence in product and process introductions and a commitment to customer enthusiasm. Shainin is pleased to be a partner with Delphi in your quest for innovation and continuous improvement. The partnership has helped both companies as we strive to meet the evolving needs of a demanding marketplace.”

Other presenting companies included Chrysler LLC, Detroit Diesel, Inteva Products, John Deere and Company and Kavlico Corporation, to name a few, showcasing manufacturing, engineering and business process problem solving and problem prevention.

For more than 20 years, Shainin tools have been used within Delphi to resolve technical, processing and quality issues, which result in increased productivity and improved quality. The Shainin system is part of Delphi’s Innovation and Continuous Improvement Methodologies (I&CIM), a toolbox for problem solving, which also includes Six Sigma, Design for Six Sigma, Shainin Green Y Validation and Red X and Robust Engineering.