Using Lean Thinking, Innovation, Creativity, People and New Technologies to Remain Competitive

Putting the Boots to Foreign Outsourcing

Technology alone has not and will not give you the completive edge. That is not to say that we do not take advantage of new technologies, we do. However, when new technologies are combined with the principles and practices of Lean Manufacturing and our creative juices start flowing, great accomplishments can be achieved in the elimination of waste. This presentation will cover how Terra Nova Shoes Limited has harnesses both new technologies combined with Lean Manufacturing principles and practices to remain competitive in the global marketplace and how instead of continuously outsourcing to foreign countries it is able to bring product back home for manufacturing. Topics will include: leadership, commitment & dedication, expectations, communications, resistance to change, team building, training, creating a lean culture, idea gathering, employee involvement, corrective and preventive actions and creating a continuous improvement mindset. It will also cover Lean Manufacturing tools used to transform our operations including the adoption of the Toyota Sewing System (TSS), Zero Defects Approach, Plant Layout and Material Handling, 5S and Visual Management, Quick Changeover/Set-ups, Single Piece Flow, Cellular Manufacturing, Total Productive and Preventive Maintenance and Standardized Work. Equipment replacement will also be covered and where and how new technologies are ideas can be found.

Terra Nova Shoes Ltd. is a privately held company (owned by Kodiak Holdings Inc.) based in Harbour Grace, Newfoundland. It was founded in 1972 as a safety work boot manufacturing plant. Its first production facility being in Harbour Grace, in a building that had previously been used as a shoe manufacturing plant. Four years after the company started, the factory burnt to the ground, destroying most of the machinery. In the rebuilding process, the destroyed machinery was replaced with the latest state-of-the-art technology. In 1977 another related facility was acquired in Markdale, Ontario and this expansion facilitated a broadening of the style catalogue when protective safety dress shoes and boots were added to the product list. The new facility also added warehousing closer to the markets. Subsequently a national sales office was opened in Toronto, Ontario with sales staff located throughout North America and selected agents in various countries, to sell the production of both facilities.

In the initial stages the footwear had PVC injected soling and stuck-on PVC soles. As technology developed this went from PVC, injected SBR rubber and stuck-on PU soles to injected dual density PU/PU, PU/Rubber and TPU. Much of Terra Nova’s strength is found on the factory floor. With technology constantly evolving, the management team continues to visit the major shoe machinery expositions and Terra Nova Shoes continues to invest in equipment/systems to keep the company in a leadership position in both styling and production.

Kodiak Holdings Inc. purchased the company and affiliated companies on April 6, 2005.

David Haire, Quality Manager/Continuous Improvement Coordinator

David Haire is the Quality Manager/Continuous Improvement Coordinator at Terra Nova Shoes Ltd., a division of Kodiak/Terra. He was transferred to this position in September 2005. Prior to this appointment, David served as the Production Manager.

David has held a number of leadership positions during his career. In addition to those mentioned above he was Production Control Manager, Quality Manager and Quality Supervisor at Dana, Brake Parts Canada Inc., Guelph Facility.

David currently sits as the chair of Fluent Manufacturing Consortia in Newfoundland, whose purpose is to work collectively and individually in pursuit of lean – to improve productivity, profitability, morale, and simplicity. Using Lean Manufacturing principles and practices David has lead a series of continuous improvement activities aimed at waste elimination and the pursuit of perfection.