Toyota Production System Highlights
Labels: automotive-lean-manufacturing, culture, flexbile-assembly, flexible-manufacturing-model, kaizen, pull-systems, toyota-production-system, tps
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Labels: automotive-lean-manufacturing, culture, flexbile-assembly, flexible-manufacturing-model, kaizen, pull-systems, toyota-production-system, tps

... "Employing the leanest of lean manufacturing techniques, Think will do no body or parts production itself. " ...
Labels: automotive-lean-manufacturing, electric-vehicle, think-auto
... " ... it seems fitting that The Machine That Changed the World, the seminal 1990 book on lean manufacturing as practiced by Toyota Motor Corp., is now being reissued. " ...
Labels: automotive-lean-manufacturing, chrysler, ford-lean-manufacturing, general-motors, lean, toyota

... "Stoppages at Visteon could bring big headaches for British car plants. ... Lean manufacturing techniques mean carmakers rarely keep large stocks of components. " ...
Labels: automotive, automotive-lean-manufacturing, lean-manufacturing, lean-principles, lean-supply-chain, lean-techniques, supply-chain
... "The Schrader story is an enlightening one demonstrating that, with investment in automation (brought about by a rigorous pursuit of lean manufacturing techniques and continual improvement), Western European manufacturers can compete ... " ...
Labels: automation, automotive, automotive-lean-manufacturing, competitive, improvement, lean-manufacturing, lean-techniques, project
... "Dunston brings a broad range of experience in manufacturing and supply chain management to American Woodmark. He comes to American Woodmark from Diamond Innovations, a leading industrial supplier to the automotive, electronics and aerospace industries, where he was vice president, Global Operations. In this position, he was tasked to significantly reduce operating costs within China, Europe and the U.S. Prior to this, he worked as vice president of operations for BBA Fiberweb, a complex fabric and laminate manufacturing company. Here he instituted the roll-out of a continuous improvement program with training in both 6-Sigma and Lean Manufacturing. " ...
Labels: automotive, automotive-lean-manufacturing, country-china, electronics-manufacturing, improvement, lean-supply-chain, region-asia, supply-chain, training
... "Izzy Galicia, Vice President of Client Services for The Corporation for Manufacturing Excellence (Manex) will keynote Collaborate 2006 being held October 10th – 12th in Huntsville, Alabama. The conference is hosted by the Society of Manufacturing Engineers (SME) in partnership with the Alabama Aerospace Industry Association and the Alabama Automotive Manufacturers Association. Mr. Galicia and Manex are well known for their work helping enterprises transform their organizations through Lean Manufacturing. As part of a panel of industry leaders, Mr. Galicia and executives from Toyota, Lockheed Martin, and Northrop Grumman will kick off the event by sharing an industry perspective on innovative technology applications and processes, including Lean Manufacturing, supply chain integration, and workforce development. " ...
Labels: automotive, automotive-lean-manufacturing, conference, event, lean-expert, lean-supply-chain, manufacturing-excellence, shingo-award, supply-chain, toyota

... "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. " ...
Labels: assembly, automotive, automotive-lean-manufacturing, product-development, results
... "Despite its huge popularity in the automotive and high-tech industries, Lean Manufacturing hasn't experienced the same high success rate in the pharmaceuticals industry, where complex process manufacturing processes are used. This is according to the results of a recent survey of more than 1,500 pharmaceutical manufacturers conducted by Invistics, a developer of manufacturing performance optimization solutions for complex, asset-intensive industries.
The recently conducted 2006 survey showed that while more than half of the respondents said their companies have implemented Lean, Six Sigma or Operational Excellence, less than half of those Lean initiatives have produced satisfactory results. This is due to the fundamental complexities of the pharmaceutical manufacturing process, which produce challenges not found in simple high-volume manufacturing plants that can dedicate production equipment to specific product lines, such as automobiles and computers. " ...
Labels: automotive, automotive-lean-manufacturing, manufacturing-excellence, pharmaceutical, results

... "Omnex, Inc. and the Automotive Industry Action Group (AIAG) announced the formation of a global training partnership offering Lean/Six Sigma training to AIAG members. As part of the agreement, Omnex will represent AIAG in India. With offices in Chennai, Bangalore, Pune, and Delhi, Omnex has earned a solid reputation throughout India as a provider of Lean/Six Sigma and automotive consulting solutions. " ...
Labels: automotive, automotive-lean-manufacturing, training

... "Engineers often talk about lean manufacturing but the Mazda MX-5 is the best example I know of putting the principle into production and watching it pay off. " ...
Labels: automotive, automotive-lean-manufacturing
... "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. " ...
Labels: achieve, assembly, automotive, automotive-lean-manufacturing, change, competitive, country-china, kanban, lean-enterprise, manufacturing-software, pull-systems, region-asia, toyota

... "United Plastic Group's newest Mexico plant will be ISO 13485 certified and FDA registered. The plant will service a diversified group of products, as do UPG's plants in the US, Europe, China and Monterrey, Mexico. Customers in the medical, consumer, automotive and electronics industries will be able to take advantage of the advanced processing, engineering and lean manufacturing capabilities provided by the new facility. " ...
Labels: automotive, automotive-lean-manufacturing, country-china, electronics-manufacturing, region-asia

... "Mr Imai is the globally renowned lean guru and a pioneer in leading the Kaizen philosophy of continuous improvement which has it roots in the automotive manufacturing industry. " ...
Labels: automotive, automotive-lean-manufacturing, conference, improvement, kaizen

... "The implementation follows the Timken Kunsebeck plant's successful pilot with Ultriva's lean software across three of its suppliers, which began in May 2005. Implementing Ultriva's lean manufacturing software, which replaced traditional purchase order processes, has already resulted in lead-time reductions of more than 30 percent, the elimination of many stock-outs and significant inventory reductions. Based on pilot results, Timken's Kunsebeck plant is targeting a 20 percent reduction in inventory and inventory carrying costs in 2006. The company also anticipates significant reductions in expediting, storage space, lead times, and overtime, as well as increased buyer and planner productivity. " ...
Labels: automotive, automotive-lean-manufacturing, manufacturing-excellence, manufacturing-software, pull-systems, results

... "Onbelay Automotive Coatings based in Chatham, Ontario, installed Plantnode on both their E-coating and Power Coatings lines to identify production bottlenecks in their manufacturing process. " ...
Labels: automotive, automotive-lean-manufacturing, manufacturing-software, operational-efficiency
... "The DCR repair process utilized at the Metro Toyota facility employs lean manufacturing principles that involve task-specific, highly trained technicians working with cutting-edge equipment and tooling. The model is designed to streamline workflow and enable the repair operation to become dependable and offer a high-level of consistency in guaranteed quality and vehicle delivery ... " ...
Labels: automotive, automotive-lean-manufacturing, employee-involvement-teams, lean-principles, toyota
... "Toyota claims to have developed the principles after the war and Nissan adopted them, introducing the concept of minimum waste and maximum efficiency to its new plant in Sunderland in the 1980s at a time when the British car industry was plagued with over-manning and underperformance. Kaizen and lean manufacturing are similar in concept, while Six Sigma, another efficiency model is driven more by technical improvements. " ...
Labels: automotive, automotive-lean-manufacturing, lean-principles, toyota, toyota-kaizen, waste
... "Solectron Corporation, a leading provider of electronics manufacturing and integrated supply chain services, announced successful certification for Solectron FinePitch to AS9100 Rev B, the quality management system specific to the aerospace industry. AS9100 certification is a strategic milestone for Solectron showcasing our comprehensive quality management system that enables us to deliver world-class quality products and services to our customers, said Misha Rozenberg, senior vice president and chief quality officer, Solectron. Solectron Production System, or SPS, our proven and industry leading Lean Six Sigma methodology, facilitated the AS9100 certification. We are very proud to add aerospace quality assurance certification to our growing list of manufacturing quality compliance standards worldwide. First published in May 1997 by the SAE (Society of Automotive Engineers) as AS9000, the AS standard is currently known as AS9100, Rev B, and is recognized by all major aerospace OEMs. " ...
Labels: automotive, automotive-lean-manufacturing, class, disciplined-approach, electronics-manufacturing, lean-supply-chain, solectron, supply-chain, world-class
... "The company's gross margin was 18.7%, relatively flat quarter-over quarter, despite the negative impact from higher steel costs and fuel surcharges on transportation costs. These factors offset savings and improved efficiencies from Lean manufacturing, Six Sigma and other cost reduction initiatives.
Total steel cost increases in the fourth quarter were $35 million, which were largely offset by the company's cost reduction efforts, including SGA&E restructuring savings, material cost savings, Six Sigma program savings and Lean manufacturing efficiencies as well as partial steel cost recovery from OE and aftermarket customers. Based on the company's efforts to offset increased steel costs and trends in the steel market, the company doesn't currently anticipate a significant year-over-year impact on operating results in 2006. " ...
Labels: automotive, automotive-lean-manufacturing, growth, manufacturing-flow, results, tenneco
... "The role of the successful candidates will be to implement the production plan ensuring time cost and material efficient use of resources. Due to the heavy emphasis on the production line improvements, the successful candidates will have knowledge of lean manufacturing methods and 5S. A strong working knowledge within ISO 9001 standards will be expected. " ...
Labels: 5s, automotive, automotive-lean-manufacturing
... "Among U.S. auto companies, Ford has done the best job of changing to meet the future, embracing lean manufacturing techniques in the 1990s and producing the first hybrid SUV (the Escape). Yet it still finds itself cutting manufacturing capacity to reflect shrinking market share. " ...
Labels: automotive, automotive-lean-manufacturing, ford-lean-manufacturing, job, transformation
... "eKanban controls the flow of parts and inventory levels so that material is delivered to a location only when it is needed so that no excess inventory is created. This is an important step in lean manufacturing as it provides two of the greatest financial impacts, reducing inventory and shortages. eKanban takes this process one step further by extending the system beyond the four walls of a factory and allowing electronic communication with suppliers, customers and trading partners. By enabling the same auto triggers for additional material from outside sources as it would internally, inventory and shortages can be further reduced providing even greater financial savings. This means the trigger of a sales shipment or notification of customer consumption could generate a series of material pulls throughout the multi-levels of an items bill of materials. These series of material pulls end up with not only material moves being generated but also demands to manufacture and buy without the need to run MRP. This process is capable of reducing the lead time required to react to change and the amount of stock holding required in high volume responsive industries such as automotive. " ...
Labels: automotive, automotive-lean-manufacturing, change, kanban, manufacturing-flow, manufacturing-software, sales
... "AAPICO Hitech Plc, an automotive parts company based in Thailand, implemented Oracle applications and technology to enable lean manufacturing operations, Oracle announced. AAPICO will soon be ready for fulfilling complex customer requests while reducing waste in its supply chain. AAPICO wanted to move towards a demand-driven supply chain to accommodate the just-in-time manufacturing schedules of its customers to reduce inventory and fulfillment times. The company, a progressive jig, die and automotive original equipment manufacturer (OEM) parts vendor with facilities in Thailand, Malaysia and China, supplies parts to all major car manufacturers in Thailand including Toyota, Honda, Isuzu, Ford, Mazda and Nissan. AAPICO began its migration to lean manufacturing through a pilot program with the support of Auto Alliance Thailand and Toyota. The program brought about quick success, as AAPICO received Toyota's coveted TPS (Toyota Production System) Championship Award in 2004 and again in 2005. After the conclusion of the program, the company decided to implement an enterprise software system to provide the platform for lean manufacturing and integrate the network of facilities.
After a careful evaluation of several vendors' offerings, AAPICO chose Oracle to support lean manufacturing using Oracle Database and the Oracle E-Business Suite, specifically the Oracle Supply Chain Management (SCM) suite, which includes Oracle Discrete Manufacturing, Oracle Flow Manufacturing and Oracle Order Management applications. AAPICO also selected Deloitte Consulting LLP to lead consulting services and additional software from A-Host, a Certified Partner in the Oracle PartnerNetwork. " ...
Labels: automotive, automotive-lean-manufacturing, country-china, ford-lean-manufacturing, inventory-management, lean-enterprise, lean-supply-chain, manufacturing-flow, manufacturing-software, oracle, region-asia, supply-chain, toyota, toyota-production-system, transformation, waste, waste-reduction
... "He also served as vice president in charge of stamping and components operations and vice president of stamping and general manager of lean manufacturing. During his career at DaimlerChrysler he held several other leadership positions including plant manager of DaimlerChrysler's Sterling Stamping and Warren Stamping plants. Corrington earned a bachelor's degree in sociology from the University of Kentucky and a master's degree in business administration from Central Michigan University. He also attended the Executive Development Program at Harvard University. " ...
Labels: automotive, automotive-lean-manufacturing, career, career-path
... "Named to his current position at Freudenberg-NOK in 2003, Sohi oversees all divisions of the $1 billion company, which is part of the global Freudenberg Group. With more than 16 years of engineering and management experience in the automotive, aerospace, electronics and retail sectors, Sohi is committed to the company's lean benchmark program called Growtth (an acronym for Get Rid of Waste Through Team Harmony). He has worked to integrate lean principles, Six Sigma practices and information technology to extend continuous improvement across the entire Freudenberg-NOK enterprise. " ...
Labels: automotive, automotive-lean-manufacturing, benchmark, ceo, electronics-manufacturing, lean-enterprise, lean-principles, waste
... "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. " ...
Labels: assembly, automotive, automotive-lean-manufacturing, class, marketing, world-class
... "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. " ...
Labels: assembly, automotive, automotive-lean-manufacturing, job, kanban, toyota, toyota-production-system
... "Key efforts needed include techniques to reduce inventories of parts, work in progress and finished vehicles; encouragement of independent suppliers; and focusing on lean manufacturing such as strict scheduling, small-batch production, even production throughout the work week and just-in-time shipments. " ...
Labels: automotive, automotive-lean-manufacturing
... "Bender joins Crane Co. with a broad functional skill set and background and a consistent record of successes in his past roles. He has spent a major portion of his professional career at Aerojet General Corporation, a division of GenCorp. He worked in various positions, including assignments in Engineering, Defense and Armaments, Automotive, Manufacturing, Business Development, Quality and most recently, Operations. He also has experience in functional leadership and implementation for Lean Manufacturing and Six Sigma Operational Excellence at all of the major locations within GenCorp. " ...
Labels: automotive, automotive-lean-manufacturing, career, career-path, electronics-manufacturing, manufacturing-excellence, six-sigma-career
... "Degree qualified in an engineering, industrial management or related discipline. 5 to 10 years management experience preferably within the automotive manufacturing sector. Must be able to demonstrate an ability to set and achieve targets in areas of cost, production and quality. Also possess a record of continuous improvement through application of lean manufacturing techniques. " ...
Labels: achieve, automotive, automotive-lean-manufacturing, disciplined-approach
... "Chief Executive Officer Clifford D. Nastas said, Customer interest in our Quiet Steel business continues to gain momentum; however, the near term holds a number of challenges, including increased competition for Quiet Steel and our decorative laminate products, volatility in automotive builds and higher costs related to energy. As these factors test our ability to improve margins, we will continue to look for ways to offset higher costs through the implementation of both lean manufacturing and six sigma operational excellence initiatives. " ...
Labels: automotive, automotive-lean-manufacturing, competitive, initiative, manufacturing-excellence, results
... "QAD software’s advanced manufacturing capabilities are completely scalable, simple to implement and easy to use in established manufacturing centers, new markets or new ventures. Enhancements reflect world-class production system principles and best practices for transmitting data to achieve lean manufacturing and supply visibility. " ...
Labels: achieve, automotive,