Kaizen events at HP Indigo Plant

HP teams deploy kaizen to streamline the routine at its facilities for Indigo products. ...

... "Presses are assembled strictly to order, and their just-in-time production is governed by Japanese-inspired rules of lean manufacturing. Team-driven kaizen events are used to solve problems and maximize throughput at every stage. " ...

Via Print CEO: HP Indigo plant

McLaren Auto Lean Setup for Production

McLaren Automotive launches new MP4-12C model which will be produced using a foundation of lean. ...

... "McLaren has also put a lot of effort into its production process. The U-shaped assembly line is completely open and set up for lean manufacturing and just-in-time parts delivery. " ...

Via Autoblog: McLaren Automotive supercar

Lean Manufacturing Makes Boeing Satellites Easier to Assemble

Intelsat awards Boeing a contract to build four telecommunication satellites based on Boeing's 702B satellite fleet. This satellite is designed with a flexible configuration and modular design incorporating advanced technologies. It is built using lean manufacturing techniques which ensures quality and affordability. ...

... "Using our Lean manufacturing processes, this new addition to the Boeing 702 family is also easier to manufacture and assemble, resulting in a high-quality, affordable product. " ...

Via Boeing: Intelsat Satellite Contract

Boeing's lean practices help it to differentiate in the marketplace. ...

Boeing Integrated Defense Systems uses lean: "Boeing's cost-saving Lean manufacturing practices and human space flight experience are being leveraged in its proposal to build the upper stage of NASA's Ares I rocket ... "

The company is willing to expend the effort to reduce waste from its processes. ...

Boeing Philadelphia Project implements lean flow system: "According to Hilaman, switching from a batch-and-queue system to a one-piece flow system is essential to achieving the benefits of lean manufacturing, but it can be an arduous journey. "

Bee Lean

Brushy Mountain Bee Farm has implemented lean manufacturing through the company and receives local recognition for its growth. ...

... "Applying lean principles for increasing productivity and decreasing waste led to expanding the wood storage area, the woodenware assembly area where beehives are constructed and the packaging area where workers prepare an average of 300 orders per day for shipping. " ...

Via Wilkes Journal Patriot: Beekeeping

Lean Medical Center Construction

Construction team uses lean in its processes to remove waste and improve cycle times. ...

... "To achieve those goals, the team is utilizing various combinations of lean design and construction project management methodologies enabled by emerging 3D virtual design and assembly technologies to plan, design, coordinate, detail, fabricate, and pre-assemble the various facility components. Notable among those is Value Stream Mapping which enables the team to visually represent their workflow processes and continuously look for opportunities to streamline them to deliver value faster, better, and less expensively. " ...

Via FIATECH: Innovators in Capital Projects

Discrete Assembly Portal

StationPortal provides central architecture and common Ethernet interface for distribute and disparate I/O devices. ...

... "StationPortal provides a completely new architecture for assembly support systems, greatly increasing the speed of deployment and optimization, while providing a significantly lower total cost of ownership. This product is a great fit for tasks such as error proofing, line balancing, material call, and other production support tasks. " ...

Via GE Fanuc: Architecture For Discrete Assembly Support

Locomotive Lean Manufacturing at GE

GE Lean Manufacturing leader shares his experience with implementing lean in the company's transportation business. The process of locomotive assembly offered opportunity for lean methods to reduce waste and improve cycle times. Driving adoption of lean principle in the workforce has been the primary challenge. ...

... "The idea is to create greater value with less effort by identifying and creating efficiencies. The principle has the chance to restore America to innovative and competitive leadership around the world, and the recession might give it an advantage, McDonnell said. " ...

Via Charleston Regional Business: GE Lean

GE moves beyond Six Sigma to embrace lean manufacturing. ...

GE Locomotive Lean in Transportation Division: "To meet global customer demand and streamline the entire manufacturing process, GE Transportation is studying Toyota and other Lean manufacturing leaders to develop its own production system to manufacture products with less waste, higher quality and higher value to customers than if produced by traditional means. "

GE Locomotive Factory discusses lean adoption.

GE has embedded lean techniques in many business process, including its ecomagination initiative. ...

ecomagination Report (PDF): "GE’s GHG avoidance work at GE Aviation’s outdoor aircraft engine test facility in Peebles, Ohio, where the production team used Lean manufacturing techniques to change its processes to reduce GHG emissions per engine test conducted. "


Talent recruiting and hiring at GE has placed an emphasis on lean experience and implementation. ...

GE Lean Manufacturing Engineer job: "The engineer will work with the manufacturing team to implement strategic changes to the design of locomotive cooling systems. These changes will be necessary to facilitate Lean and Standarization ... "

La-Z-Boy Lean Manufacturing

Local La-Z-Boy plant uses lean methods to position the site for long-term success. ...

... "La-Z-Boy Midwest took a careful look at their operations and determined that they could find a better solution. The plant moved to lean cellular manufacturing, which means that each piece of furniture will be built by a team within a cell, instead of separately along an assembly line. " ...

Via Neosho Daily: La-Z-Boy

Lean Manufacturing Productivity Enhancer

Boeing's CEO uses multiple methods, such as lean and voice of customer, to transform business performance. In this example, he uses lean to improve cycle times and increase production capacity. ...

... "And at Boeing he used Lean Manufacturing -- another productivity enhancement tool -- to cut in half the time it takes to assemble a 737, from 22 days to 11 days, to save hundreds of millions of dollars, and to increase capacity without adding new plant. " ...

Via BloggingStocks: CEO Biz tips

Packaging and Putaway Process Automation

Lean Workforce Impact

Boeing and union are at odds over the impact of supplier collaboration on the workforce. ...

... "As part of its lean manufacturing strategy, Boeing wants suppliers to deliver parts and components directly to the assembly line, a task traditionally performed by IAM members. " ...

Via AVIATION WEEK: Boeing

Partnership on Lean Software for Electronics Manufacturing

Manufacturing execution software will be enhanced through partnership to enable electronics manufacturing using lean techniques. ...

... "The Calavista Software team will be working with the Optimal Electronics development team to further expand and improve the capabilities of the Optel MES (Manufacturing Execution System) software suite. This will include leveraging their software development tools, processes, and both local and remote software development engineers. Optel is an integrated suite of industry-leading software modules that addresses all aspects of electronics assembly, enabling its customers to properly and quickly implement Lean Manufacturing. " ...

Via Optimal Electronics: Software Development Partnership

Boeing Aircraft Lean Production System

Boeing starts manufacturing of key airplane components as it ramps up for aircraft assembly by mid-year. Lean techniques make up its repertoire of manufacturing improvements. ...

... "To create additional production capacity to build the 787 vertical fin, the Boeing factory implemented significant improvements, including a pulse moving line featuring right-sized tooling, determinant assembly and advanced technology drilling techniques. Lean manufacturing techniques are used to enhance the quality and efficiency of its production system. " ...

Via Aero-News Network: Boeing 787 Manufacturing

Lean Manufacturing Strategy: Chrysler New Products

Chrysler Group plans to produce the new 2008 Dodge Challenger at its Brampton Assembly Plant near Toronto. The plant leverages lean manufacturing to reduce waste and accelerate efficiency. ...

... "Lean manufacturing and product development strategies also allow the Chrysler Group to bring new models, like the Dodge Challenger, to market more quickly. First revealed as a concept vehicle at the North American International (Detroit) Auto Show in 2006, it was announced this past summer that the 2008 Dodge Challenger would be going into production in 2008. " ...

Via DaimlerChrysler: Ontario to Become Home of the All-new 2008 Dodge Challenger

Lean Home Building: Modular

Company applies lean principles to modular home building ...

... "What makes the company unusual is that the modules are made in assembly-line fashion using a state-of-the-art computer numerical control (CNC) system, lean manufacturing principles and Total Quality Management. " ...

Via Skagit County Business Pulse: Link

Manufacturing Expansion: Lean Foundation

Scott Electronics expands manufacturing capacity ...

... "The equipment and employee expansion in Mexico will allow this lean facility to increase its production in the coax and POF (plastic optical fiber) business. " ...

Via ThomasNet: Scott Electronics Inc. Expands Manufacturing Capabilities in its Salem, N.H. and Nogales, Sonora Mexico Facility

Background on Scott Electronics: Scott Electronics provides quick turn with lead times from same day to 1 week for established production Kanban programs. Six Sigma and 5S implementation in all assembly cells.

Efficient Material Handling: Lean Production

Bosch Rexroth offers insights into efficient assembly operations through references and downloads. ...

... "Efficient Material Transport in Lean Production answers many questions about when to consider automation as part of an overall lean process. Download. " ...

Via Bosch Rexroth Corp: Lean Production

LMI Aerospace Lean Manufacturing Methods Improve Productivity

LMI Aerospace reports good performance in the third quarter as its lean manufacturing emphasis contributes to increased productivity in the workforce. ...

... "Ronald S. Saks, President and Chief Executive Officer of LMI Aerospace said, Our third quarter results continued a two year string of increased revenue and profits relative to comparable prior year quarters. Increasing production rates and profitable new work in the business jet, commercial aircraft and helicopter markets, as well as strong emphasis on lean manufacturing methods to improve productivity and throughput, have contributed to make 2006 the best year in our history. " ...

Via LMI Aerospace: LMI Aerospace, Inc. Announces Results for Third Quarter 2006

Lean Value Chain Efficiency

Local manufacturers in mining industry use lean manufacturing techniques in their value chain to drive efficiencies. ...

... "Lean manufacturing has done a lot for the company in two years, Raffaelli said. Assembly time for a telehandler has been cut roughly in half to 16 hours. Assembly line stations are down to five from 11. " ...

Via The Daily Mining Gazette: Terex Handlers implementing lean manufacturing ...

Kaizen Toyota Corolla Dependabiity ...

Toyota Corolla's dependability is a result of relentless focus on continuous improvement through kaizen. ...

... "Every process -- from assembly operations to the paint shop, from bringing in parts to loading finished cars on trucks or trains -- has been refined. Toyota calls it kaizen, or continuous improvement. " ...

Via SanJose Mercury: The bestselling car ever

Lean Flow Sheds Waste ...

Modern day lean flow has its roots in the early auto industry assembly line. Today's enterprises leverage Lean and Six Sigma to eliminate waste and solve problem to reduce variability, increase speed, and delight the customer. ...

... "Ford likened his Lean Flow process -- also called Lean Manufacturing, Continuous Flow and Just-In-Time Manufacturing -- to a river that flowed continuously. Anything that disrupted the flow was a waste that had to be eliminated. " ...

Via Public CIO: Trimming Waste Fast

Semiconductor Assembly: Six Sigma Certification ...

Indium Corporation, a supplier of electronics and semiconductor assembly materials, invests in certification of 11 Six Sigma green belts. The company will have opportunity to implement Six Sigma projects in their factories, located in the USA, the United Kingdom, Singapore, and China. The company believes in quality management and is ISO 9001 registered. ...

... "Indium Corporation recognized 11 individuals for achieving their Dartmouth Six Sigma Green Belt Certification. A Dartmouth Six Sigma Green Belt has demonstrated proficiency in developing and executing design experiments to support continuous process improvement at a competent level. Individuals who achieved the certification include: Stephen Foster, Mike McNamara, Bob Jarrett, Nicole Palma, Runsheng Mao, Stephen Smith, Hong-Sik Hwang, Ed Gudlauski, Leroy Page, Anthony Piccione, and Dave Sbiroli. Training for the certification was presented by Ronald C. Lasky, Ph.D., Senior Technologist at Indium Corporation and visiting professor at Dartmouth College's Thayer School of Engineering. " ...

Via Indium Corporation: Indium Corporation has 11 achieve Six Sigma Green Belt Certification ...

Lean Process: Global Manufacturing Network

Dresser, Inc. relocates its valve manufacturing plant to a new facility in the strategically-located industrial area in Brazil. The new 56,000-square-foot facility began producing control valves and pressure relief valves recently using lean manufacturing techniques. ...

... "This new Dresser facility is one of a network of global manufacturing facilities dedicated to the manufacturing of Dresser's Masoneilan control valves and Consolidated pressure relief valves for the energy and process industries. The facility provides manufacturing, assembly, testing, distribution, service and repair capabilities using the lean manufacturing techniques and processes. It will be ISO 9000 registered and will also comply with all applicable ASME code requirements. " ...

Via Dresser, Inc.: Dresser, Inc. Relocates Brazilian Manufacturing Operations to New Facility ...

Manufacturing Software: Lean Integration ...

Factory Logic collaborates with the Automation and Drives Group of Siemens AG to integrate the Factory Logic Lean software into the Siemens SIPLACE manufacturing optimization solution. ...

... "Siemens will integrate the Factory Logic Lean Operations Suite (Factory Logic) into SIPLACE manufacturing optimization solutions for the global electronic assembly market. SIPLACE is the Siemens product family name for integrated hardware, software and services solutions to support the entire SMT (Surface Mount Technology) production facility. Factory Logic is a software solution designed from the ground up to support demand-driven production scheduling and pull-based supply synchronization using proven lean methods originally pioneered in the Toyota Production System (TPS). As part of SIPLACE lean manufacturing solutions, Factory Logic will enable electronics manufacturers to perform advanced production leveling and kanban/supermarket management functions in conjunction with SIPLACE SMT machines and other Siemens solution components. Factory Logic supports an integrated approach that directly links production to actual customer demand, while maintaining the stability required for consistent, reliable, waste-free factory and supply chain operations. Siemens will sell and support the Factory Logic software as an embedded component of SIPLACE solutions globally. " ...

Via Factory Logic: Siemens to Integrate Factory Logic Lean Manufacturing Software Into SIPLACE Electronics Assembly Solutions ...

Mulally Lean Experience Ford's Benefit ...

Ford will benefit from CEO Mulally's lean manufacturing experience at Boeing. ...

... "Mr Mulally carefully studied Toyota's world-beating manufacturing in the early 1990s, though it took years before Boeing's factories incorporated much of the lean manufacturing philosophy - the 737 factory got a moving final-assembly line only in 2003, 90 years after Henry Ford invented it. " ...

Via Economist: Ford's new pilot ...

Lean Manufacturing at Technology Expo ...

Lean manufacturing success at upcoming expo ...

... "Assembly Technology Expo in Rosemont, IL.: But, by attending the event, you can find out something that he already knows: Lean manufacturing really works. " ...

Via Assembly Magazine: Lean Barrier Busting ...

Lean Manufacturing Renovation Enables New Automotive Component Launch ...

GKN implements lean at renovated facility in preparation for new product launch, such as its new power transfer unit. ...

... "GKN Driveline's Torque Technology Group is introducing a new power transfer unit (PTU) for all-wheel-drive vehicles in North America and Japan that is lighter and stronger than previous designs, while providing customers with reductions in noise, vibration and harshness. The new PTU is the result of a two-and-a-half-year development programme with DaimlerChrysler and Mitsubishi. In North America, the new unit will be available on three new 2007-model DaimlerChrysler vehicles and will be manufactured at a GKN Driveline facility in Bowling Green, Ohio. The company recently completed a multi-million-dollar renovation of the Bowling Green plant to prepare for the PTUs production launch and to optimize lean manufacturing at the facility. There are plans to add a second shift to the plant's PTU assembly line early next year. " ...

Via GKN Driveline: GKN Driveline's New Technology Saves Weight and Fuel ...

Jaguar Lean Revamp Drives Efficient Production ...

Jaguar Halewood manufacturing site has transformed its assembly lines to levels of efficiency that are the envy of Europe. ...

... "Halewood has been producing cars since 1963 with the Ford Anglia. It stopped producing Ford brand products in mid-2000 and has been completely revamped using lean manufacturing principles for efficient production. " ...

Lean Revamp Efficient Production: Via The Observer: Merseyside on the edge as its drive to success is threatened ...

Sealy Lean Manufacturing Expansion ...

Sealy expands its manufacturing footprint in Pennsylvania, leveraging lean techniques in the design and operations. ...

... "Sealy will employ Lean Manufacturing techniques in the design and operation of the plant. Sealy has 25 other plants in North America, including a second components plant in Delano, about 30 miles south of Mountaintop. Sealy also operates a mattress assembly plant in Clarion, Pennsylvania." ...

Via Sealy Inc.: SEALY EXPANDS MANUFACTURING OPERATIONS IN PENNSYLVANIA WITH NEW WILKES-BARRE AREA FACILITY: New Facility Dedicated to Latex Foam Bedding Products Will Create 100 Jobs ...

Lean Software: Visteon SAIC China JV ...

QAD software enables the lean manufacturing success of the Visteon SAIC joint venture in China. ...

... "QAD Inc., a leading provider of enterprise software solutions for global manufacturers, announced that Yanfeng Visteon Automotive Trim Systems LTD has deployed enterprise software applications from QAD to enable lean manufacturing operations and achieve exceptional inventory and manpower efficiencies. The implementation of QAD's Global Enterprise Edition. QAD GXE has enabled Yanfeng Visteon to gain dramatic reductions in material inventory, substantial reductions in stock space and enhanced data for logistical support and personnel savings. Yanfeng Visteon, a joint venture between SAIC Motor Corporation Limited, one of China's largest automotive manufacturers, and Visteon International Holdings Corporation, one of the world's preeminent automotive component manufacturers, is the leading supplier of spare parts for cars and trucks within China.

Like North American auto and truck manufacturers, the joint-venture company has been faced with the need to change its business processes to reduce inventory costs, enable higher productivity, and meet the requirements associated with sequencing assembly projects. The company's streamlining of operations using QAD provides cost as well as competitive benefits. QAD's software and expertise in lean systems has allowed Yanfeng Visteon to gain a critical advantage over other Chinese companies. Using QAD GXE, Yanfeng Visteon has cut materials inventory, reduced stock area, and cut logistics staff, enabling the company to achieve efficiencies that are unmatched by other enterprise solutions available today, as noted by company executives. Based on Toyota standards for lean manufacturing that are widely accepted by the automotive industry, QAD's Lean Manufacturing solution helps manufacturers effectively use Kanban systems to align inventory with demand for pull-based replenishment. It integrates electronic representation of Kanban processes with core ERP functions to provide comprehensive level loading, tracking and visibility of production, and supports electronic Kanban as well as physical card-based visual systems. " ...

Lean Software: Visteon SAIC China JV: Via QAD: Visteon-Shanghai Joint Venture Turns to QAD to Enable Lean Manufacturing ...

Lean Six Sigma Supports Joint Venture ...

Adam Cort explores the success of Lean Six Sigma at an exemplary plant in the UK ...

... "Then came CAT's 2001 Six Sigma initiative, whereby the company mandated that operations worldwide would adopt the methodology. According to Clark, Six Sigma helped Perkins Shibaura focus its quality efforts. " ...

Lean Six Sigma Supports Joint Venture: Via ASSEMBLY: Crossroads in the UK ...

Perkins and Japanese manufacturer Ishikawajima Shibaura machinery, Ltd. (ISM) launched a joint venture company, Perkins Shibaura Engines, Ltd., and a manufacturing facility in 1996 adjacent to the Perkins manufacturing plant in Peterborough, UK. The original product was the Perkins 100 Series engine. ISM has been manufacturing agricultural equipment and engines since the 1940s and is one of Japan's leading suppliers of small engines and tractors. ISM is part of Ishikawajima Harima Industries - (IHI), one of Japan's largest industrial companies.

Perkins Engines is a wholly owned subsidiary of Caterpillar Inc. and the world's leading supplier of off-highway diesel and gas engines in the 4 - 2000 kW (5 - 2600 hp) market. Perkins' key strength is its ability to tailor engines precisely to meet customers' requirements. More than 300,000 engines are manufactured every year -- that's one every minute -- to 21,000 different specifications. For more than 75 years Caterpillar Inc. has been building the world's infrastructure and, in partnership with its worldwide dealer network, is driving positive and sustainable change in every continent. With 2002 sales and revenues of $20.15 billion, Caterpillar is a technology leader and the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines.

Toyota Kaizen Improvement Leads in Stamping Labor Productivity ...

Toyota kaizen process allows its to maintain leadership in productivity measures, according to recent Harbour Consulting report North American automaker performance. ...

... "Toyota again led in stamping labor productivity, although its 1.42 stamping hours per vehicle degraded 3.6% from 2004. Toyota regained the lead in press productivity with a record 792 average parts per hour. Harbour uses a stamping index that weighs each of several measures in a process that creates a composite score of stamping productivity. On that basis, Toyota's Cambridge stamping shop ranked first, followed by Toyota Georgetown, Honda East Liberty, Honda Marysville and Toyota Princeton. Of the 10 best stamping plants, Toyota had three; Honda, two; DaimlerChrysler, Ford, General Motors, Nissan and NUMMI, one each. In total stamping labor productivity Nissan ranked third, behind CAMI, with 2.11 HPV. Chrysler Group was fifth (behind NUMMI), improving 6.7% to 2.64 HPV. As in assembly, Toyota is among the best in the industry, said Harbour. It is not a matter of spending more than competitors. It reflects regular kaizen improvement activities and the flexibility that comes with well coordinated engineering and manufacturing. Ford has also shown a renewed commitment to upgrade its stamping technology after several years of limited investment, and its performance is showing a steady climb despite aging equipment. " ...

Via Harbour Consulting: PRODUCTIVITY GAP AMONG NORTH AMERICAN AUTOMAKERS NARROWS IN HARBOUR REPORT 2006 (PDF) ...

Lean Manufacturing Software: Advanced Production Techniques ...

QAD lean manufacturing software enables techniques for advanced production. ...

... "VKI Technologies, based in Quebec, is deploying QAD MFG/PRO eB2 technology from California-based enterprise software provider QAD Inc., to support the company's lean manufacturing initiatives and related advanced production techniques. VKI Technologies produces coffee-brewing equipment for the North American market and licenses its patented technology to equipment manufacturers in Europe and Japan. According to Robert Primeau, director, Business Strategies and Customer Support, VKI is focused on eliminating parallel systems and expanding use of QAD software to ensure a consistent standard for enterprise operations – from finance to the factory floor and supply chain, and in the future, customer self-service. VKI's manufacturing facilities encompass several operational processes and just-in-time (JIT) techniques such as mix model assembly lines, point-of-use storage, cellular manufacturing in its sheet metal department and Kanban card-controlled production, all of which have increased the company's manufacturing flexibility and reduced its response time for specific customer orders. " ...

Lean Manufacturing Software: Advanced Production Techniques: Via QAD: VKI Technologies Brews Potential for Business Expansion with Enterprise Technology from QAD

Six Sigma Industrial Engineer Position ...

Industrial engineer position is available ...

... "An understanding of Six Sigma in a manufacturing environment is preferred; previous experience in a high speed assembly manufacturing environment is also a plus. " ...

Six Sigma Industrial Engineer Position: Via Spokesmanreview: Classifieds

Kaizen Team Identifies Waste ...

The kaizen experience is described in this article. ...

... "After completing time trials and suggested improvements on Snow Cell 10, our Kaizen team began to identify waste in each step of the assembly process. Each team member observed a new work station to find ways to reduce waste in motion. " ...

Kaizen Team Identifies Waste: Via Appleton Post-Crescent: Kaizen best learned through participation ...

Six Sigma Repeatability Wafer Manufacturing ...

DEK establishes Six Sigma repeatability as its goal for printing in wafer manufacturing. ...

... "DEK has set out a vision for the future that demands wafer level accuracy, six-sigma repeatability and first time print as fundamental capabilities for next generation screen printing in SMT and semiconductor assembly. " ...

Six Sigma Repeatability Wafer Manufacturing: Via DEK International: Assemblers require radically new technologies on five-yearly basis, says DEK ...

Lean Transformation Keynote: Raytheon Leader ...

... "Richard Schuler, the director of Lean implementation at Raytheon's Integrated Air Defense Center (IADC) in Andover, MA, will give the keynote address for the Nepcon East/Electro and Assembly East event in Boston this May. " ...

Lean Transformation Keynote: Raytheon Leader: Raytheon's Lean Director to Keynote Nepcon East - Circuits Assembly ...

Via Raytheon Company: Special Interest Stories: Raytheon's Integrated Air Defense Center Claims Shingo Prize for Excellence in Lean Manufacturing: "Dan Ryan, vice president of Operations for Raytheon's Integrated Defense Systems (IDS) business, recently accepted the Northeast Shingo Prize for Excellence in Manufacturing at a dinner reception held on the campus of the University of Massachusetts, Boston, on Wednesday, Sept. 14, 2005. "

Leverage Lean Manufacturing Capabilities: Growth through Acquisition ...

General Cable grows through acquisition as it leverages lean manufacturing capability to new facilities. ...

... "Beru brings to General Cable a profitable, low cost assembly operation and available capacity to support this growth, said Roger Roundhouse, Vice President and General Manager of General Cable's Wire Harness and Assembly business. We look forward to working closely with our new associates at the Cuernavaca facility to further enhance the profitability and regional growth of this business through the application of our industry leading assembly processes and the leveraging of our world class lean manufacturing capabilities, he concluded. General Cable (NYSE:BGC), headquartered in Highland Heights, Kentucky, is a leader in the development, design, manufacture, marketing and distribution of copper, aluminum and fiber optic wire and cable products for the energy, industrial, specialty and communications markets. " ...

Leverage Lean Manufacturing Capabilities: Growth through Acquisition: Via General Cable: General Cable Corporation Acquires Mexican-Based Automotive Aftermarket Business ...

Lean Manufacturing: Chrysler Doing It Right ...

Lean manufacturing implementation at Chrysler Group positions it for success as its sister division must make hard choices. ...

... "New DaimlerChrysler AG CEO Dieter Zetsche defended job cuts at the company's Mercedes division, saying in an interview made available Saturday that the division could learn something about lean manufacturing from Chrysler Group. " ...

Lean Manufacturing: Chrysler Doing It Right: Via The Charlotte Observer: Zetsche defends cuts, says Mercedes could learn from Chrysler

Additional resources on Chrysler lean manufacturing progress:

Lean Manufacturing, Kaizan, Kanban, Just In Time Articles: "Chrysler Group is moving up the rankings quickly, helped by a 9.5% improvement in engine productivity. Since 2001, the company has gained 19% in productivity across assembly, stamping and powertrain measures."

The Daimler-Chrysler Collision - Another merger in search of that elusive synergy By James Surowiecki: "And there is the hope that Chrysler's lean manufacturing style will help Daimler shake up a company that is still heavy with layers of middle management. Chrysler makes four times as many cars as Daimler with fewer than half the workers ... "

The Tale of a New Manufacturing Economy: "This adverse downturn was significant in another way. After years of denial, it drove many manufacturers, such as the US automotive industry, to become more productive by embracing the Toyota Production System (aka, lean manufacturing). After implementing lean, Chrysler raised its total productivity by over 7% last year ... "

Boeing Lean Manufacturing Production System ...

Boeing will build the 787 on a new production system based on lean manufacturing principles. ...

... "The company also has adopted a new lean-manufacturing production system based on Toyota's. The new assembly line in Everett for the 787 will be the ultimate application of lean principles, with suppliers sending in huge completed sections from around the globe for a three-day assembly process. " ...

Via KING5 Seattle News: Successor to Boeing 737 likely to be built in state ...

Additional resources on Boeing lean manufacturing principles:

Via Boeing: Environmental Reports - Creating - Build it Lean: "These ideas are called Lean Manufacturing, which draws on the insights and skills of the men and women whose hands form our products. It starts at the detail level, where small increments of waste can go unnoticed in the great push to assemble an airplane. By stepping out of their regular routine and taking stock of their work space and processes, with the coaching of a manufacturing expert, our employees have mounted a grass-roots revolt against waste."

Via Boeing: Lean Enterprise Successes: "To date, IDS application of Lean principles has led to products with fewer parts, are easier to build and support, have higher quality and are more affordable. The net result is higher customer satisfaction, better opportunity for growth and increased shareholder value."

Via Boeing: All Systems Go - Vol. 2, No. 3: "The introduction of Lean manufacturing to the shop floor in 1999 changed everything. Today the Mesa site is one of the company's Lean showpieces and is a candidate for the prestigious Shingo Prize."

Advanced Lean Manufacturing Techniques for Jaguar XK ...

Jaguar XK assembly facility utilized advanced lean manufacturing techniques. ...

... "The creation of a new Jaguar sports car with an aluminium-intensive body structure represents a significant manufacturing accomplishment. A new, dedicated aluminium assembly facility at the Castle Bromwich plant alongside some of the most advanced lean manufacturing techniques in the car industry are major aspects of the XK manufacturing story. John Naughton Castle Bromwich Plant Director, Jaguar Cars. " ...

Advanced Lean Manufacturing Techniques for Jaguar XK: Via Car Pages: The First Production Jaguar XK Rolls Off In Birmingham ...

Lean Six Sigma: Customer Service Differentiates ...

Firm combines Lean Six Sigma efficiency with customer service and responsive business models to differentiate itself in a globally competitive market space. ...

... "That propels them from a parts maker, a target for Chinese competitors, to a contract manufacturer offering design, engineering, components, sourcing, testing and assembly. That's an array of value-added products and services that are a harder target. The four Wendorff companies also pursue operating excellence through lean and Six Sigma disciplines. " ...

Lean Six Sigma: Customer Service Differentiates: Via JS Online: City finds strength in manufacturing

ZeroDefect Manufacturing: Subaru Committment ...

ZeroDefect Manufacturing: Subaru Committment: In the latest brochure for the 2006 B9 Tribeca, Subaru highlights its benchmark development and manufacturing process. Subaru of Indiana Automotive, Inc. manufactures the B9 Tribeca for the global market and made a major investment in retooling the factory. A zero defect process is used to ensure quality and customer satisfaction. Quality checks are built into every step of the assembly process and pokayoke control boxes to track the process steps. Also, a significant investment in robotics was made to increase the flexibility in manufacturing. ...

Lean Manufacturing: Dramatically Cut Turnaround Time ...

Lean Manufacturing: Dramatically Cut Turnaround Time: Via Yahoo! Finance: Motorcar Parts Featured on CNBC's Power Lunch ...

... "Mike Hegedus recapitulated MPAA's 40 year corporate history, highlighting the Company's impressive improvements in efficiency through the adoption of lean manufacturing, which allowed it to dispense with the traditional assembly line and dramatically cut turnaround time. " ...

Six Sigma QA Position: Aviation Industry

Six Sigma QA Position: Aviation Industry: Via Flight International: Quality Assurance Position, Europe\UK, Wynnwith

... "You will be educated to a degree level with a minimum of 5 years background in Mechanical Engineering in manufacturing, assembly or service sector, with 2 years leadership experience, you will also be require to have knowledge of Health and Safety Management Systems, also some knowledge of aerospace quality systems and certification, FAA/JAA/CAA certification schemes, Six Sigma and Advanced Qual tool would be desirable. " ...

Enterprise Lean Six Sigma ELSS

Deloitte contributes enterprise Lean Six Sigma, ELSS, services to the Save Your Factory initiative.

Enterprise Lean Six Sigma ELSS: Via FANUC Robotics: FANUC Robotics America, Inc. Forms New Relationship with Deloitte Consulting LLP to Help North American Companies Improve Factory Efficiency

... "We're enthusiastic that Deloitte Consulting has joined the Save Your Factory consortium as we help companies to more comprehensively evaluate the pros and cons of moving manufacturing off-shore and make a decision that's right for their organization, said Rick Schneider, president and CEO of FANUC Robotics America, Inc. Deloitte Consulting's extensive offerings include enterprise lean and six sigma (ELSS), which are process improvement and change management services that provide solutions to companies facing global competition. " ...

FANUC Robotics America, Inc. designs, engineers and manufactures industrial robots and robotic systems for a wide range of applications including arc and spot welding, material handling (machine tending, picking, packing, palletizing), material removal, assembly, paint finishing and dispensing. The company also provides application-specific software, controls, vision products, and complete aftermarket support. After 23 years of success, FANUC Robotics maintains its position as the leading robotics company in the Americas. A subsidiary of FANUC LTD in Japan, the company has facilities in Chicago; Los Angeles; Charlotte, N.C.; Cincinnati and Toledo, Ohio; Toronto; Montreal; Aguascalientes, Mexico; and Sao Paulo, Brazil. Over 145,000 FANUC robots are installed worldwide.

DFMA Design For Manufacture

Via American Society of Mechanical Engineers: DFMA to RP, ASAP

Mastering DFMA, or design for manufacturing and assembly, can accelerate time to market and lower the total life cycle costs of new products and their facilities. Here are background and references on DFMA ...

... "The concept of DFMA was developed in 1980 by Geoffrey Boothroyd and Peter Dewhurst, professors of industrial and manufacturing engineering at the University of Rhode Island in Kingston. The following year, they founded Boothroyd Dewhurst Inc. to market proprietary DFMA packages. " ...

Via ACC: Acquisition Community Connection: Design for Manufacturing and Assembly ...

... "DFMA is a systematic analysis of the design of an assembly or subassembly to reduce product cost by simplifying its design, assembly, and manufacturing without impacting performance. The analysis allows you to determine the theoretical minimum number of parts that must be in the design for the product to function as required. As you identify and eliminate unnecessary parts, you eliminate unnecessary manufacturing and assembly costs. " ...

Via Army Logistics Management College: Smart Simple Design

... "The Smart Simple Design initiative encompasses two processes. The first step is using Design for Manufacture, Design for Assembly, and Design for Service (DFMAS) software in the early stages of the design process to achieve significant benefits from reducing costs and logistics support requirements. The second step of the Smart Simple Design initiative is assembling a design oversight and comparison process team to reduce the number of needed parts and standardize parts across different product lines. " ...

Via American Machinist: Technologies to reduce production costs ...

... "Companies can slash costs by improving the design process at its beginning. Design for manufacturing and assembly (DFMA) software includes a design-formanufacture module, with which engineers obtain early cost estimates on parts or products, and a design-for-assembly module, which they employ to determine the best methods to manufacture products. " ...

DFMA consists of complementary Design for Assembly (DFA) and Design for Manufacture (DFM) software. Engineers use DFA software to reduce the cost of a product by consolidating parts into elegant and multifunctional designs. DFM software then helps engineers quickly judge the cost of producing the individual components of the new design. Used together, DFM and DFA software give engineers an early cost profile of product designs, providing a basis for planning and decision making. When performed in the earliest stages of concept design, DFMA analysis has the potential to dramatically reduce manufacturing and other product life-cycle costs before they are locked in. DFMA software operates in MicrosoftÒ Windows 98, Windows 2000, and Windows XP.

Boothroyd Dewhurst, Inc., is a winner of the 1991 National Medal of Technology Award, presented by President George H. Bush. Other recipients of the award have included William Gates of Microsoft Corp. and Robert Galvin of Motorola Inc. Boothroyd Dewhurst is dedicated to continually developing the DFMA knowledge base through its integrated software programs, workshops, consulting services and international conferences. For more information, contact Boothroyd Dewhurst, Inc., 138 Main Street, Wakefield, R.I. 02879, USA. Tel.

PokaYoke Human ErrorProof System ...

PokaYoke Human ErrorProof System: Via Autoworld: Proton Tanjung Malim Plant - Building The Next Generation of Cars ...

... "A Human Error Proof (POKAYOKE) System in the assembly equipment is installed in critical and safety related torque devices (bolts, nut runners, wrenches, etc). Any operation missed by the operator will cause the line to stop automatically and the operator will need to manually reset the torque. " ...

Automotive Manufacturing Pokayoke ...

Automotive Manufacturing Pokayoke: Via TACO Group: Tata Ficosa Automotive Systems Limited

... "Multi-stage fully automatic assembly and stage-wise testing lines like the Pokayoke system have been successfully installed and commissioned for outer rear-view mirrors and command and control systems. " ...

Pokayoke Quality Assurance Technique ...

Pokayoke Quality Assurance Technique: Via Inside Outcomes July 2002

... "Pokayoke is a quality assurance technique developed by a Japanese manufacturing engineer to eliminate defects in a product by preventing or correcting them early. The Pokayoke system is an important step in Eaton's efforts to significantly improve quality control by verifying each step of assembly. Eaton installed the system to increase production, reduce waste and maintain electronic records for heavy-duty truck transmissions produced by the facility. " ...

Founded in 1832, Lockwood Greene is America's oldest professional services firm in continuous operation for industrial and power engineering and construction. With headquarters in Spartanburg, South Carolina, Lockwood Greene serves U.S.-based Fortune 500 and international companies around the globe, including North America, Latin America, Asia-Pacific and Europe. Lockwood Greene serves the manufacturing, process, power and institutional markets.

SixSigma Quality Supplier: Belton Group ...

SixSigma Quality Supplier: Belton Group: Via Seagate: Seagate Technology News Release Seagate Technology Honors Supply Chain Excellence for 2005

Belton Group recognized a Six Sigma quality supplier by Seagate ...

... "The Belton Group, a leading manufacturer of Arm Coil Assembly and Hook-Up, was this year's Outstanding Supplier in the Mechanical Components category. In addition to delivering on aggressive volume requirements, Belton consistently outperformed its peers to meet Seagate's quality, Six Sigma, Lean Manufacturing and technology metrics. " ...

Seagate is the worldwide leader in the design, manufacturing and marketing of hard disc drives, providing products for a wide-range of Enterprise, Desktop, Mobile Computing, and Consumer Electronics applications. Seagate's business model leverages technology leadership and world-class manufacturing to deliver industry-leading innovation and quality to its global customers, and to be the low cost producer in all markets in which it participates. The company is committed to providing award-winning products, customer support and reliability to meet the world's growing demand for information storage.

Lean Manufacturing Facility Design ...

Lean Manufacturing Facility Design: ModusLink Expands its Utah Operations ...

Facility design incorporates lean manufacturing techniques to achieve high-performance supply chain ...

... "The new facility adds 174,624 square feet of operational space and capacity to the current global footprint. Employing lean manufacturing techniques, the center was designed and equipped with highly skilled personnel, equipment, systems and business processes to implement the most efficient and cost effective supply chain solutions. " ...

ModusLink is a leading provider of global supply chain management solutions. The company provides global technology clients in the software, hardware, telecommunications and wireless markets with customized supply chain solutions that reduce risk and time to market and improve efficiency and productivity. ModusLink's services include demand planning, sourcing and procurement, manufacturing support, kitting and assembly, fulfillment, full-cycle logistics, systems integration and development, customer support and optimization consulting. Headquartered in Waltham, Massachusetts, ModusLink maintains 37 facilities in 13 countries and employs 3,900 people worldwide. The company is a subsidiary of CMGI, Inc.

Additional resources on lean manufacturing facility designs:

Facilities In Lean Manufacturing Strategy: Lean Manufacturing is all about adding value and avoiding waste. Facility planning (land, buildings, equipment, furnishings) provides the physical capability to add value. ...

Items included in facilities design are plant location, building design, plant layout, and materials handling. The focus of this text is on designing lean manufacturing facilities. This means that all aspects of production should work together to eliminate waste.

Facilities Design for Lean: The lean facility design concentrates on adding value at each activity. This is done by creating one piece flow through cells dedicated to product families. Pull is created through kanban and visual systems. Quick setups are a necessity.

Lean Manufacturing Centre Excellence ...

Lean Manufacturing Centre Excellence: Media.Ford.com: JAGUAR SCORES QUADRUPLE SUCCESS IN LATEST J.D. POWER INITIAL QUALITY SURVEY AS EUROPE'S LEADING NAMEPLATE

... "Jaguar's Halewood Plant manufactures the luxury Jaguar X-TYPE and employs 2400 people. It is recognised throughout the industry as a centre of excellence for Lean Manufacturing and the plant has won several awards for its best practice production and logistics processes. In 2000, a significant investment was made in Halewood to transform the plant from a mass-production assembly plant for the Ford Escort to a world class manufacturing facility for the Jaguar X-TYPE. It meant that for the first time Jaguar would have a plant that housed all four stages of the production process under one roof totally new body construction and final assembly facilities, along with refurbished press and paint shops. " ...

Aerospace Lean Manufacturing Systems ...

Aerospace Lean Manufacturing Systems: CUSTOMER AIRCRAFT MASS PRODUCTION UNDERWAY FOR NEW SJ30-2 TWINJET: Sino Swearingen Aircraft Corporation Deliveries to Start Later This Year ...

... "Sino Swearingen Aircraft Corp. (SSAC) announced that new aircraft Serial number 0006 slated for customer delivery has been mated with the wings, tail assembly, and landing gear and has moved out of the mating jig to its next production position in San Antonio facility. Customer aircraft Serial Number 0007 fuselage and wings are near completion at our Martinsburg West Virginia facilities and about to be shipped to San Antonio for assembly in the mating jig. Lean manufacturing systems are setting up in both facilities. " ...

Sino Swearingen Aircraft Corporation is certifying the new SJ30-2 in San Antonio TX with 430 employees in four facilities totaling over 220,000 sq ft in the USA Coast To Coast. The Company continues spectacular acceleration of the FAA certification projected to be final in the second half of this year 2005. The new Sino Swearingen SJ30-2 business jet is a high performance, long range, intercontinental, twinjet aircraft with an incredible 2,875 sm range and one of the highest cruise speeds in the industry to Mach .83 (560 mph). The SJ30-2 will operate at altitudes to 49,000 feet and maintain a “Sea Level Cabin” to 41,000 ft with the best pressurization in the business jet world, 12 psi. The new SJ30-2 will also have certification for single pilot operations. Sino Swearingen Aircraft Corporation business plan is aggressively geared to become the world's leading aircraft producer by creating a family of cost-efficient, high performance, high-quality, superior technology, business jets.

Lean Accounting: Summit in the Fall ...

Lean Accounting Summit

... "Flexware Innovation announces the first annual Lean Accounting Summit to take place in Dearborn, Michigan September 22-23, 2005. The event is being sponsored by Flexware, the Association for Manufacturing Excellence (AME), and the Society for Manufacturing Engineers (SME) and will feature more than 20 lean accounting thought-leaders. Notable presenters will include, among others, Tom Johnson, Professor of Business Administration at Portland State University, Brian Maskell, President of BMA Inc., and Orry Fiume, 2004 Shingo Prize winning author of Real Numbers: Management Accounting in a Lean Organization." ...

Flexware was founded in 1996 by Scott Whitlock as a manufacturing IT and automation services company. The company quickly formed a niche in Manufacturing Execution Systems (MES), helping companies strategize, select, and implement custom and commercial-off-the-shelf systems. Flexware employs more than 30 manufacturing systems professionals and support staff, serving clients in the pharmaceutical, medical device, assembly, and automotive industries. In 2002 Flexware defined a unique continuous improvement process called highlandpath to guide clients through operational and enterprise excellence transformations. This group utilizes this proprietary process to find high leverage, high meaning opportunities and seizes those opportunities with the best of Lean, Six Sigma, and other continuous improvement methodologies.

Lean Six Sigma Award ...

News Center - LMC Awards ...

... "Lean/Six Sigma Award: Lockheed Martin Corporation gives the Lean/Six Sigma Award to affiliated facilities that attain significant cost avoidances as a result of applying the Lean/Six Sigma tools and philosophies. 2003 Neutron Generator Production Center 14400: Straight to the Top Award for the group's establishment of a Lean/Six Sigma Standard Work Cell in the neutron tube final assembly area that resulted in significant cycle time reductions." ...

Toyota TPS Kaizen Concepts ...

U.S.-Japan Investment Initiative ...

... "Toyota Motor Corporation has expanded local production in the U.S. since starting production in 1986 at New UnitedMotor Manufacturing (NUMMI) in California, a Toyota/General Motors joint venture. As a result of the expansion, localproduction reached 990,000 units, and North America-made vehicles accounted for 59.2% of their U.S. sales in 2002. Itcontributed to the U.S. economy and employment, as well as to improvement of production efficiency in the U.S.automobile industry through introduction of the Toyota production system, such as the concept of Kaizen. Theircumulative U.S. investment has reached $12 billion and they directly employ 30,000 workers. Moreover, in February 2003 they announced a plan to construct a fourth U.S. vehicle assembly plant (for pickup trucks)in San Antonio, Texas by 2006. After beginning operation of the plant in 2006, their production capacity in the U.S. willreach 1.35 million units, their cumulative U.S. investment will become $13 billion, and they will employ 32,000 workers.In addition to the fact that Texas is the top U.S. truck market, an enthusiastic welcome from state and local governmentscontributed to the decision to construct of theplant in Texas. The state and local governments coordinated the initiativeto assemble a package of state and local financial incentives to attract the plant." ...

Kaizen Continuous Improvement Drives Performance Excellence ...

PERFORMANCE EXCELLENCE ...

From South Carolina Office of State and Budget ...

... "Continuous Improvement: Sometimes called Constancy of Purpose, this is a principle used by W. Edwards Deming to examine improvement of product and service. It involves searching unceasingly for ever-higher levels of quality by isolating sources of defects. It is called Kaizen in Japan, where the goal is zero defects. Quality management and improvement is a never-ending activity." ...

Established as a separate entity in 1984, the Office of State Budget is responsible for the development and oversight of the process for preparing the annual state budget. This includes requests for funds, allocations of funds, and the responsible utilization of funds to achieve the needs of state government. The Office provides data to the Governor's Office for its use in making annual budget recommendations to the General Assembly and works closely with the legislature throughout the budgetary cycle.

Lean Manufacturing Engineer Position Available ...

UK job vacancies, online job search - jobs.telegraph.co.uk

... "Technical support for operations activities, including quality, H&S and cost reduction. Advancement of lean manufacturing concepts. Qualified to HND/Degree level in mechanical or industrial engineering discipline, you will ideally have a minimum of 5 years experience within a similar role. Experience within an engineering environment including fabrication and assembly would be a distinct advantage" ...

Ford Lean Manufacturing Career Moves ...

St. Paul Pioneer Press | PUBLIC COMPANY NEWS

... "Ford plant, home of the Ford Ranger pickup, has a new manager. Jerome Hamilton, the St. Paul Ford plant's former head of lean manufacturing, replaces Mona Rinehart as plant manager. Rinehart started a new job earlier this month as plant manager of two Ford assembly plants in Ohio. Ford officials called the transfer a routine personnel change." ...

Heijunka Scheduling ...

Heijunka Production Scheduling ...

... Production is initiated by retrieving a card from the Heijunka box slot. Then the parts are kitted; the nameplate is stamped; and the kit is taken to the workcell and placed in the incoming location. The first assembler in the workcell takes the kit; checks the paperwork for the model and options required; and performs the assembly steps for the first station. The partially-assembled unit is then passed to the next station where further assembly steps are performed. ...

BioInformatics Software Supports Collaboration in Distributed Environments ...

BioInformatics Software Supports Distributed Environments: New software version is used for optimized integration and retrieval of biological information in distributed environments ...

BioInformatics software company enhances product to facilitate collaboration ...

From Biomax Informatics AG ...

... Biomax Informatics AG releases version 5.4 of the BioRS Integration and Retrieval System, which provides powerful tools for accessing both public and proprietary data in a secure and distributed environment. To facilitate data sharing between members of a large working group, databanks integrated at any location can be accessed by users at other locations. Once a databank and corresponding indices have been integrated from a remote BioRS instance, cross-references can be created locally for quick access to information in other integrated databanks. ...

Biomax Informatics AG (Martinsried, Germany), a leader in the development of customized bioinformatics solutions, was founded in 1997 as a spin-off of the GSF-MIPS academic research group, now the German Research Center for Environment and Health-Institute for Bioinformatics (GSF-IBI). Founded by Dr. D. Frishman, Dr. K. Heumann and Prof. Dr. H. W. Mewes, Biomax developed the well-known Pedant-Pro™ Sequence Analysis Suite, the HarvESTer™ EST Assembly and Clustering System, and other bioinformatics tools used in metabolic pathway, proteomics, and gene expression analyses. The BioRS Integration and Retrieval System provides the most sophisticated and easy-to-use system to search and integrate heterogeneous public and proprietary databases including both flat-file and relational. The BioRS system is a fast and flexible way to simultaneously search multiple databases using convenient Web interfaces. Researchers can quickly search biological databases while system administrators can easily integrate flat-file and relational databases for multiple users.