Deal with Mistakes using Poka-Yoke

Simple tools are illustrated to prevent mistakes, using poka-yoke techniques.

Flextronics Kaizen Practices Drive Improvements for the Customer

Flextronics Paderborn Germany site has mapped its value streams and continually implements improvements using Kaizen techniques. These improvements accelerate the efficiency of the operations over time, as individual changes may be hard to notice, but cumulative effects are signficant. ...

... "We are using the Kaizen cards to record and implement improvements to our workspace. Even changes that seem little at first can have a major impact on the quality and speed of our production. " ...

Via evertiq: Flextronics Lean




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DFSS Discovers Hidden Customer Needs

Various types of innovation are discussed. Innovative ideas must be generated and shaped into achievable concepts. Understanding the voice of the customer and hidden customer needs can be improved by leveraging the DFSS process. ...

... "The process begins by first understanding that there are hidden customers who must be discovered, and then working together to find the best way to satisfy their needs. Today, the Design for Six Sigma (DFSS) is a systematic methodology to provide the means to attain new services and innovative designs. " ...

Via American Society for Training & Development: Innovation

Nummi American Lean System

Toyota leadership will wrestle with decision on the future of the Nummi site which was used to refine American lean techniques with General Motors. GM has reorganized its way out of the joint venture with Toyota. ...

... "For Toyota, Nummi served as a beachhead for it to push deeper into the U.S. market and also a learning lab to figure out how to effectively use American labor within the Japanese company's lean manufacturing system." ...

Via Wall Street Journal: Toyota Leadership

Tour of the Nummi manufacturing facility.

GM Cancels Pontiac Vibe, Manufactured at Nummi Site: "General Motors has decided to discontinue production of the Pontiac Vibe by the end of August 2009. The Vibe is produced at the New United Motor Manufacturing Incorporated (NUMMI) facility jointly operated by GM and Toyota in Fremont, California. "

Immelt on GE Lean Operational Capability

GE CEO Jeffrey Immelt discusses the company's Michigan investment and its core capabilities, such as lean and Six Sigma, which positions the company to compete effectively in many markets. ...

... "Through the use of lean manufacturing techniques, our 100-year-old Erie factory can export to Mexico and Brazil. Operational capability is a core part of GE's strategy. " ...

Via Wall Street Jouranl: GE CEO Immelt Speech

Fiat Lean Production System

Chrysler will implement Fiat's version of lean manufacturing, the Fiat Production System. ...

... "Fiat, based in Turin, uses a system that emphasizes measuring every aspect of work and stopping inefficiencies, Hill said. It is similar to Toyota Motor Corp.’s highly regarded lean-manufacturing system ... " ...

Via Bloomberg: Chrysler

Mobile Applications in Manufacturing

Utah Manufacturers Get Shingo'd

EFI Electronics and Autoliv are recognized for their lean manufacturing performance with Shingo Prizes. Both companies were committed to lean operations, which required changes such as equipment modifications and layout changes. ...

... "Autoliv, the maker of automobile airbag systems and one of the state's largest manufacturers, was awarded the top Shingo Prize for two of its five Utah locations. " ...

Via Salt Lake Tribune: Shingo prize

EFI Electronics Shingo Silver Medallion (PDF)

Shingo reception highlights ...



Autoliv uses team-based kaizen systems (PDF).

Autoliv's implementation of lean has been a journey (PDF).

Autoliv is recognized in the industry for its impressive lean manufacturing system. ...

Green Belt Blended Learning

SUNY at Buffalo is offering a blended course of online and on-location education for Green Belt in Six Sigma, slated for the Fall - Sept. 3 through Nov. 12. ...

... "Green Belt Blended Learning course, offered by UB's Center for Industrial Effectiveness (TCIE) in Fall 2009. Led by Master Black Belt Tom Miller, TCIE's senior business process performance manager, the 10-week program immerses candidates in the initial step of the Six Sigma methodology ... " ...

Via SUNY, University at Buffalo: Fall 2009 Green Belt Certification Course

An Apple a Day and Six Sigma Healthcare

Wegman's leader discusses efficient healthcare through Six Sigma principles. ...

... "Speranza discussed the programs that the Rochester Business Alliance’s Healthcare Initiative has developed, including the implementation of six sigma principles in local hospitals and Wegmans’ communitywide eat well, live well challenge. " ...

Via RocNow: Business

Process Excellence

Lean Six Sigma Integrates Solutions for Sustainability Improvement

IBM builds partnerships to solve sustainability problems with an integrated set of cross-industry solutions, that leverage Lean Six Sigma principles for improvement. ...

... "Green Sigma is an IBM solution that applies Lean Six Sigma principles and practices to energy, water, waste and GHG emissions throughout a company's operations -- transportation systems, data centers and IT systems, manufacturing and distribution centers, office facilities, retail space, research and development sites, etc. It combines real-time metering and monitoring with advanced analytics and dashboards that allow clients to make better decisions that improve efficiency, lower costs and reduce environmental impact. " ...

Via IBM: Green Sigma Coalition

Lean Investment Leads to Payoff

Internal investment is an attribute of companies poised to weather the current business cycle and emerge in a stronger competitive position. ...

... "Toyota's margins were higher because it invested heavily in automated production systems and lean manufacturing initiatives over many years and, as a result, was much better positioned to weather the current crisis than its American competitors. " ...

Via Motley Fool: These Companies

GM Kaizen

GM's Tom Stephens brings his personal kaizen to the product development job. ...

... "I'm here to defend Tom, for one simple character trait: He's a tinkerer. He has devoted his entire life to making things a little bit faster, a little bit more durable, a little bit more reliable. " ...

Via Automotive News: Tinkering GM

Factory within Factory Model at Littelfuse

Littelfuse team is recognized by ASQ for its achievements in product performance, quality, handling, process efficiency, and financial results. The team focused resources and floorspace to improving its fuses. ...

... "The American Society for Quality (ASQ), sponsor of the competition, recognized the team for its application of Lean/Six Sigma methodology to eliminate the chance of loose caps in square nano fuses. The Littelfuse team demonstrated how it leveraged its factory within a factory model and applied an arsenal of quality tools to reduce chemical handling, improve cap-retention strength by 166 percent, reduce cycle time by 52 percent and trim manufacturing costs by 9 percent. " ...

Via Littelfuse: ASQ Honors for Lean/Six Sigma

Lean Eliminates Seven Wastes

Using Charts to Detect Process Trends

Traditional statistical process control charts may obscure signals of process instability, especially if there is a product-only focus. Charting process performance can catch instability sooner. ...

... "The Short Run Control Chart takes care of those problems by coding the expected variation (in this case the target) out of the data and plotting data for all the parts on one chart. " ...

Via Hertzler Systems Blog, The Data Heads: Short Run SPC Example