Automotive Customer Satisfaction

Customer satisfaction statistics are available for the auto industry, showing a growing disparity for American automakers except for Saturn. ...

... "Hit with record losses, American auto manufacturers are also suffering from slumping customer satisfaction. No domestic car maker is represented among the top four nameplates, but the bottom three in the industry are all American brands. Yet customer satisfaction for the industry as a whole remains at an all-time high (unchanged at 82), and one American car maker, GM's Saturn, shows considerable improvement, climbing 5% to tie its all-time high from 1998." ...

Via American Customer Satisfaction Index: American Automakers Fall Further Behind Foreign Competition (PDF)

Lean 5S in Workplace

Sportscar manufacturer adopts lean principles to improve quality and efficiency. ...

... "The programme began earlier this year with a consultant-run workshop on using the 5S principles in the workplace. " ...

Via Works Management: Westfield Embraces Lean

Toyota Supplier Performance Award

Toyota recognizes its suppliers to keep quality moving forward constantly. ...

... "Autoliv was awarded with the Superior Performance Award for its continuous efforts in reengineering of existing products and shifting of production to low cost countries. This distinction, the highest of its kind, which Toyota awards to its suppliers, was received by Benoit Marsaud, COO and President of Autoliv Europe, during Toyota Motor Europe's annual supplier conference in Brussels. " ...

Via Autoliv Inc: Superior Performance Award from Toyota

Electric Vehicle Factory Tour

Toyota Kaizen Way Improves Customer Service

Toyota exec shares insights on Toyota and its kaizen principles. ...

... "Our customer service philosophy is fix it right the first time and to have lifelong customers. The term kaizen is one of the pillars of the Toyota way. " ...

Via The Augusta Chronicle: Toyota exec

Toyota Kaizen Carries Through to Motorsports

Toyota uses kaizen techniques to coordinate continuous improvement across its motorsports teams. The teams have confronted major challenges with this mindset. The knowledge of new race teams is leveraged across the organization. ...

... "Kaizen, a Japanese term commonly translated as continuous improvement, has been the ethos for Toyota's Motorsports operation. The way kaizen is achieved by the various teams in all three levels of NASCAR racing is by working together as one as much as possible. " ...

Via FOX Sports: NASCAR

Design for Six Sigma Automotive Perspective

Upcoming seminar on Design for Six Sigma in the automotive industry. ...

... "Breakthrough Management Group (BMG) would like to invite you to attend an upcoming session in Detroit on Nov. 8. This complimentary, educational event will focus on how DFSS is being used to address some of the major challenges in auto manufacturing ... " ...

Via Breakthrough Management Group: Design for Six Sigma (DFSS) Executive Seminar for Auto Suppliers and Manufacturers

Related:

Specializing in Lean, Six Sigma and Innovation, BMG works with leading companies around the globe to help in-source new capability and develop new core competencies.

Six Sigma Path to Leadership by David Howard Treichler, Ronald D Carmichael: DFSS Product Process Fusion

Six Sigma Innovation Stigma

Bob Nardelli's choice as leader at Chrysler is questioned, as his Six Sigma approach could stifle innovation needed to revive the ailing automaker. ...

... "But as a command-and-control executive, weaned on Six Sigma, Nardelli isn't the obvious leader for a company whose future depends on innovation. " ...

Via Business Week: Chrysler

Automotive Quality Leader of the Year

American Axle & Manufacturing (AAM) Co-Founder, Chairman & CEO Richard E. Dauch is recognized by the American Society for Quality, Automotive Division as its 2007 Quality Leader of the Year. ...

... "Providing our customers with exceptional quality products is a top priority at American Axle & Manufacturing. Since AAM was founded in 1994, we have emphasized continuous improvement in our operations utilizing Six Sigma, Lean Manufacturing and Total Quality Management Systems. Today, we are proud to say that we have achieved an industry-leading 9 PPM as measured by our largest customer. " ...

Via American Axle: Richard E. Dauch Receives Quality Leader Award from ASQ Automotive Division

Total Quality Index for Automotive Customer Satisfaction

Hyundai achieves recognition in the Total Quality Index for customer satisfaction. ...

... "Hyundai produced the most segment leaders of any automotive manufacturer, according to Strategic Vision's Total Quality Index(TM) (TQI), which measures total vehicle satisfaction among new car owners. Clinching the top spot in three distinct vehicle segments is a first for Hyundai. The Strategic Vision results released today placed the Hyundai Azera sedan atop the large car segment, the Entourage (tied with the Kia Sedona and Nissan Quest) in the top spot for the minivan segment and the Santa Fe on top in the small sport utility vehicle (SUV) segment. " ...

Premier Customer Satisfaction Survey

Lean Training Goes On Tour

Lean culture differentiates Japanese from US companies.

... "Instead of paying people to retire, a likely Japanese alternative would be to put people on kaizen (continuous improvement) teams, capitalizing on their experience and problem solving potential instead of paying them to stay at home. ... World Class Manufacturing is not a short-term concept. Justifying the hard work and application of resources to the improvement process is difficult if the focus is on quarterly reports. A fundamentally change in the way success is measured must be adopted if our economy is to remain viable and sustainable. " ...

Toyota Continues their March Past US Automakers: Lean Enterprise Training Announces Six City Tour Kicks off in Oregon ...

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

VP SixSigma Quality Process

Metaldyne makes leadership appointment. Metaldyne is a leading global designer and supplier of metal-based components, assemblies and modules for transportation related powertrain and chassis applications. ...

... "Dickerson will lead Metaldyne's quality initiatives and the company's focus on Six Sigma, including implementing process improvements in key operational areas. In this role he will also work closely with his counterparts at Metaldyne's parent company, Asahi Tec Co., Ltd., to support synergies in the areas of safety, MOS, quality, launch, product lifecycle management, material procurement and logistics. Metaldyne recently was acquired by the Shizuoka, Japan-based chassis and powertrain component supplier, which does business in the passenger car/light truck and medium/heavy truck segments." ...

Via Metaldyne: Metaldyne Appoints Steve Dickerson Vice President, Quality, Six Sigma and Process ...

GE Six Sigma Creates Auto Industry Leaders

XPEL Technologies appoints Steven J. McAuley, GE Six Sigma business leader, as its new Chief Executive Officer. This GE veteran can leverage XPEL's product strengths and information technologies as a competitive advantage. ...

... "Prior to joining UAG, Mr. McAuley served as Managing Director and Corporate Officer for G.E. Fleet Services within the United Kingdom. During his tenure with G.E., he was responsible for assets of $900 million, annual revenues of $225 million, and a workforce of 350. Mr. McAuley has been six-sigma certified through the G.E. Corporation. " ...

Via XPEL: AUTO INDUSTRY EXECUTIVE JOINS XPEL AS CEO

India Kaizen: Automotive Manufacturing

India automotive manufacturing uses kaizen techniques to drive benefits. ...

... "In areas like factory layout and selection of equipment, production and quality control systems, kaizen and suggestion schemes, and the importance of training, Maruti followed Suzuki's advice with great benefit. " ...

Via Business Standard: Read

Visteon Lean Supply Chain

The lean supply chain at Visteon and its automotive customers can be impacted by any workforce events. ...

... "Stoppages at Visteon could bring big headaches for British car plants. ... Lean manufacturing techniques mean carmakers rarely keep large stocks of components. " ...

Via Times UK: Visteon ...

Logistics Six Sigma Savings: 3M Brazil

3M will outsource pallet management to CHEP, trasitioning from exchange pallets. Using the Six Sigma DMAIC process, 3M validates significant room for improvement in its pallet operation. It expects to realize benefits with potential cost reductions for transportation and storage. ...

... "To determine whether CHEP services were appropriate for the company's operations, 3M used Six Sigma processes, solicited feedback from wholesale and superstore retail customers and conducted a comprehensive reference call at the Brazilian facilities of a leading global consumer products company. During the review process, managers identified a chance to decrease loss of pallets and reduce the quantity of renewed equipment derived by costumer returns. " ...

Via CHEP: 3M Brazil Sees Cost Savings With CHEP Program

CHEP is the global leader in pallet and container pooling services serving many of the world's largest companies. The company has more than 7,700 employees and operates in 44 countries. Combining superior technology and an asset base of more than 280 million pallets and containers, CHEP offers its customers exceptional value, a platform that enables reduction in customer product damage, and an environmentally sustainable logistical solution. Supply chains served include consumer goods, produce, beverage, and the automotive industry. With global partners that include Procter & Gamble, SYSCO, Kellogg's, Kraft, Nestle, Ford and GM, CHEP is known for Handling the World's Most Important Products. Everyday.

3M Brazil uses a number of management methods in its operations, such as theory of constraints in its supply chain. ...

Via AGI-Goldratt Institute: TOC World 2000 Video Presentations: "3M Brazil successfully applies the Theory of Constraints to their Sales and Operational Plan (SOP) to define their ideal sales mix in terms of addressing the market, the impact on production, and to evaluate the impact on their bottom line. "

In addition to its efficiency focus, 3M Brazil focuses on sustainability in its manufacturing operations. Its skills in pollution prevention are showcased here. ...

3P Examples: "3P team from 3M Brazil's Itapetininga facility replaced the solvent-based paper treatment process the plant used to manufacture packaging, medical and masking tapes with a new, water-based process. As a result of this change, the facility reduced solvent emissions by over 45 tons per year. "

Continuous Improvement Project: Automation Complements

Automotive suppliers leverage automation and continuous improvement to remain competitive. ...

... "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 ... " ...

Via ProcessingTalk: Link

Manufacturing Leader: Lean Roll-Out Experience ...

American Woodmark appoints manufacturing leader with Lean Six Sigma implementation experience. ...

... "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. " ...

Via American Woodmark: Cary Dunston Named Senior Vice President of Manufacturing, American Woodmark

Manufacturing Excellence Keynote at Engineering Conference ...

Lean manufacturing expert will keynote upcoming engineering conference. ...

... "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. " ...

Via Manex: Shingo Award-Winning Lean Expert, Izzy Galicia, to Keynote SME Collaborate 2006 Conference ...

Automotive Manufacturing: Kaizen Methodology

Bentley manufacturing event will examine success through methods such as kaizen. ...

... "At Bentley on 18 October, manufacturing managers from across Britain will be examining how attaining high levels of production excellence by applying world class standards and techniques like Japanese-inspired kaizen methodology can lift the sector out of the doldrums. They will also have the opportunity to visit the Bentley production line. " ...

Via The Manufacturing Alliance: The exclusive network for senior management in engineering ...

Machine Vision Supports Six Sigma Performance Levels ...

Six Sigma repeatability supported by machine vision automation ...

... "To ensure reliable quality control, faster inspection, and good return of investment, the vision-based dimensioning system for the spark plug production line can measure eccentricity and offset to an accuracy of 0.01mm with a six-sigma repeatability of better than 10% of the tolerance value. " ...

Via ISA: Machine vision finds more uses from automotive to nuclear inspections ...

Kaizen Events Kanban Discipline Outperforms Expectations ...

Investment VP sees company's kaizen experience as enabling expectations to be outperformed. ...

... "Since our initial investment Breeze has obtained three new patents, centralized materials purchasing, instituted Kaizen events that have led to cost reductions and adopted Kanban disciplines to streamline inventory management, said American Capital Vice President Helen Yang. As a result, it has significantly reduced its leverage and impressively outperformed our expectations. This quick de-levering, coupled with the Company's attractive growth prospects and continued cost reductions have created conditions for a dividend recapitalization. American Capital first invested in Breeze in August 2004, supporting Wind Point's acquisition. Founded in 1948 in Saltsburg, Pennsylvania, Breeze invented and patented the first worm-drive hose clamp, which uses a worm screw configuration to tighten, seal and connect pipes and tubes. " ...

Kaizen Events Kanban Discipline Outperforms Expectations: Via American Capital: American Capital Invests $52 Million in Portfolio Company Breeze Industrial Products Corporation



Breeze Industrial Products Corporation with facilities in Saltsburg, Pennsylvania, Auburn Hills, Michigan and Frittlingen Germany, is a leading global supplier of proprietary and patented steel clamps for the heavy duty truck, automotive, and industrial markets. Offering 13 product lines for varied clamping applications, the Company sells approximately 13,000 different SKUs marketed under the Breeze, Torca, and Clamp-All brands.

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 ...

Lean Pharma Evolution ...

Survey shows pharma industry implementation of lean six sigma is evolving slowly. ...

... "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. " ...

Via Invistics: Traditional Lean Manufacturing May Not Be Rx for Pharmaceutical Companies ...

Lean Six Sigma Training AIAG ...

Partners will provide Lean Six Sigma training to AIAG ...

... "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. " ...

Automotive Industry Action Group (AIAG) and Omnex announced global training partnership offering Lean/Six Sigma training to AIAG members.

Lean Manufacturing Automotive Industry ...

Robin Roberts sees Mazda MX-5 as a lean exemplar. ...

... "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. " ...

Lean Manufacturing Automotive Industry: Via icLiverpool: Mazda MX-5 1.8i ...

SixSigma Recognition: FreudenburgNOK by Ford ...

Freudenburg NOK is recognized by Ford for its innovative use of DFSS Design for Six Sigma in the pre-production process of automotive component manufacturing. ...

... "In honor of the Technology Specialist's quality efforts, Freudenberg-NOK recently received a Recognition of Achievement Award from Ford Motor Co. for its consumer-driven Six Sigma accomplishments. The award is part of the automaker's World Excellence Awards program, which recognizes suppliers who not only achieve the highest levels of cost, quality and delivery, but who also embrace the vision to build Ford's legacy and drive innovation to new heights. The Recognition of Achievement Award, earned by only nine suppliers in 2005, honors suppliers who impact customer satisfaction by providing significant contributions in key designated areas including: environmental leadership, consumer-focused technology and consumer-driven Six Sigma.

Freudenberg-NOK's Advanced Vibration and Acoustics (AVA) group was charged with optimizing the sealing isolation system and the noise, vibration and harshness (NVH) characteristics for a cam cover design. AVA has developed techniques to synergize sealing and NVH, which are typically opposing phenomena. Utilizing Design for Six Sigma techniques, the Freudenberg-NOK engineering team improved the product pre-production, also optimizing cost savings and increasing customer value. Six Sigma, which focuses on measuring quality and allowing for no more than 3.4 defects per million parts, is one of the pillars of Freudenberg-NOK's Growtth program focused on superior quality, service and productivity. Freudenberg-NOK has 61 Six Sigma black belts on staff and has completed 155 Six Sigma projects to drive superior quality, enhance reliability and help automakers and tier one customers to reduce costs. " ...

Six Sigma Recognition: FreudenburgNOK by Ford: Via Freudenberg-NOK: Freudenberg-NOK Recognized for Six Sigma Achievement by Ford Motor Co ...

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 Manufacturing Plant: New Facility for UPG ...

UPG readies its third plant in Mexico ...

... "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. " ...

Via Yahoo! Finance: United Plastics Group Inc. Announces Plans for Contract Manufacturing Facility in Baja Region of Mexico ...

Kaizen Creator Addresses Conference ...

Masaaki Imai addresses Logistics Conference ...

... "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. " ...

Via Ferret: Father of Kaizen visits Australia

Lean Software Replaces Purchase Orders ...

Timken implements Ultriva lean software to eliminate purchase orders and pull materials into the production process. ...

... "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. " ...

Lean Software Replaces Purchase Orders: Via Ultriva: Timken Deploys Ultriva Lean Manufacturing Software In Its European Automotive Division ...

Lean Manufacturing: Software Identifies Production Constraints ...

Manufacturing firm uses software to find production constraints. ...

... "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. " ...

Lean Manufacturing: Software Identifies Production Constraints: Via Shoplogix: Onbelay Automotive Coatings Increases Operational Efficiency with Shoplogix Plantnode ...

Plantnode is a hybrid web-based software application designed on an open platform to integrate with existing production equipment, analyze real-time performance, and evaluate machine productivity. Plantnode's built-in intelligence goes beyond raw data collection to provide a fully integrated production and performance management application; differentiated by the ability to compare real-time data against planned estimates. Plantnode is proven to increase Overall Equipment Effectiveness (OEE) and enables machine level visibility on a 24x7 basis with automatic escalations and interactive processes to drive higher levels of operational efficiency, quality, and performance.