Next-gen manufacturing plant investment

In response to market momentum, GM begins to invest in its manufacturing future. ...

... "it would invest about $890 million to upgrade five North American plants to build the next-generation V8 engine for its full-sized pickup trucks. " ...

Via Reuters: GM to invest

Bajaj lean automotive techniques

Nissan partners with Bajaj to compete profitably in the small, cost effective automotive market with a global product offering. ...

... "Nissan will utilize Bajaj's lean manufacturing techniques for the low-cost offering. Most -- if not all parts -- will be sourced from within India as well, allowing Nissan to cut overhead costs by reducing labor costs and the amount spent on shipping. " ...

Via Automobile Mag: Nissan Tata Nano-Fighter

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

Williams Controls Lean India Plant

Williams Controls deploys Lean in its new Indian manufacturing site. ...

... "Patrick W. Cavanagh, Williams Controls President and Chief Executive Officer: Our new state-of-the-art manufacturing facility will employ the latest Lean Six Sigma techniques to help us better serve our Indian customers and give us the capacity needed to expand with customer demand. " ...

Via CNN: India Manufacturing Plant

Lean production assessment kickstarts Volvo truck manufacturing implementation

Lean manufacturing is implemented at Volvo Truck production facility in Australia. The plants implementation strategy includes understanding the baseline performance: "In order to become more productive and efficient, Volvo has decided to implement the Japanese production philosophy Lean Production. With consideration to this, Volvo wanted a comprehensive investigation of the current situation in the production. " http://bit.ly/bgiU3V

Lydall Realizes Savings from Lean Six Sigma Program

Lydall sees improvement in results with Lean Six Sigma benefits realization. ...

... "We are encouraged by the improvement in financial results by our Performance Materials and Thermal/Acoustical segments. Operating income from the Performance Materials segment in the current quarter was $2.9 million, an improvement of $1.8 million from the second quarter of 2009. In our Thermal/Acoustical segment, we were able to record a nominal profit due to higher sales as well as from savings beginning to be realized from the consolidation of our North American automotive facilities and from our Lean Six Sigma program. In the third quarter of 2009, we remained focused on managing working capital and improving cash generation. We continued to reduce our inventory levels in the current quarter as inventories were lower by $5.7 million, or 15%, compared to June 30, 2009. For the second consecutive quarter we generated cash from operating activities, and have now generated over $2 million in cash from operating activities in the nine months ended September 30, 2009. " ...

Via Lydall: FINANCIAL RESULTS FOR THE THIRD QUARTER

WABCO Lean Manufacturing Applications

WABCO, tier one supplier to commercial vehicle industry, is able to navigate challenging business conditions and achieve profit while revenue is off significantly. The company is applying lean methods to enable cost savings and is seeing some growth in emerging markets. ...

... "WABCO continues to anticipate and mitigate adverse market conditions through orderly cost reduction measures, systematic productivity initiatives and further applications of lean manufacturing, among other accomplishments that our people have honed over the years in our globally connected culture of operational excellence, said Esculier " ...

Via WABCO: Q3 2009 Results

The Penske System: Planning, Appearance, and Discipline

Roger Penske prepares to take on the Saturn franchise. Expect his leadership principles to develop this channel for growth as the automotive manufacturing shifts from General Motors to a different partner. ...

... "His racing team is known for its meticulous planning, its spit-and-polish appearance and, above all, its discipline. He has applied the same principles in other parts of his automotive empire, and gotten sterling results. " ...

Via New York Times: Roger Penske, Saturn

Lean Flow Software for Manufacturing

Apriso revenues hold steady during this challenging business cycle, as the company recaps its accomplishments which includes release on lean flow software developed with Accenture and customer input. ...

... "Apriso launched FlexNet Lean Material Flow, a preconfigured solution for quick deployment to better synchronize material flows, lower costs and improve collaboration across operations. Developed in collaboration with Accenture, this solution leverages best practices gained over years of Lean manufacturing deployments. Valeo, a $12B industry leading global automotive supplier, played an important role in the design of this solution by identifying key Tier 1 automotive supplier requirements while ensuring the solution adhered to Lean principles. " ...

Via Apriso Corp: First Half 2009 Results

Ford India Lean Manufacturing Techniques

Ford transforms its India operations in preparation for production of a new car. The plant has been retrofit and will leverage lean techniques for success. ...

... "The transformed Maraimalai Nagar Ford plant is built around an array of new lean manufacturing techniques to make it ultra-efficient and its products cost-competitive even in the hotly contested sub-B segment in India and other growth markets. " ...

Via Paddock Talk: Ford Investment In India

BMW Lean Manufacturing

BMW uses creative techniques to satisfy inventory needs without introducing waste to the process. ...

... "Meeting customer desires at a price the customer is willing to pay is essential to BMW's success, he said, adding the company is marrying lean manufacturing with its build-to-order building method. " ...

Via Greenville: BMW future

Battery Innovation to Spur Manufacturing Transformation

President Obama makes significant investment in the advancement of battery technology as a catalyst to transform the country's transportation to electric vehicles and accelerate the transition of the manufacturing base to new products. ...

... "The $2.4 billion is the single largest investment ever in advanced battery technology for hybrid and electric drive vehicles, and coupled with another $2.4 billion in cost share from the award winners, it will result in the creation of tens of thousands of manufacturing jobs that are much needed in places like Elkhart. Places like Elkhart have been hit particularly hard as manufacturing jobs have disappeared, but this new investment provides $39 million for Navistar to create or save hundreds of jobs in Elkhart. " ...

Via The White House: Spurring Innovation, Creating Jobs

Toyota Growth Over Quality

Toyota is shaking up its leadership ranks as it prepares to retool the company during the challenges of this business cycle. ...

... "But he said the company, famous for caution and self-reflection, strayed when growth, not quality, became its main concern. " ...

Via New York Times: Toyota Restructures

Poland Tychy Flexible Manufacturing

Fiat's Poland automotive manufacturing site is powered by flexible cells and agile workers. ...

... "At Tychy (pronounced TICK-ee), one secret is flexibility: The latest robotic technology is balanced by workers who can quickly shift models to match demand. " ...

Via New York Times: Poland on Small Car Manufacturing

Fiat Lean Production System

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

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

Via Bloomberg: Chrysler

Utah Manufacturers Get Shingo'd

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

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

Via Salt Lake Tribune: Shingo prize

EFI Electronics Shingo Silver Medallion (PDF)

Shingo reception highlights ...



Autoliv uses team-based kaizen systems (PDF).

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

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

Lean Investment Leads to Payoff

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

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

Via Motley Fool: These Companies

GM Kaizen

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

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

Via Automotive News: Tinkering GM

Toyota Lean Obeya Seeks Savings

Toyota marshals its workforce to seek lean manufacturing savings, in war-room style, using an obeya to coordinate and accelerate cost improvements. The obeya is used to manage the project, monitor progress, and adapt to dynamic conditions with project managers living in the space. Toyota's Woodstock site is deploying these aggressive techniques to achieve savings. ...

... "But with the global automobile industry mired in its worst crisis in a quarter-century, even Toyota’s latest standards for lean manufacturing are not good enough. " ...

Via New York Times: Toyota Lean Strategy

The Toyota obeya strategy pays off. ...

Obeya via shmula: "Obeya was used to bring decisions much earlier in the product lifecycle ... "



Obeya projects leverage strong communication techniques. ...

New Product Development via Goodrich (PDF): "Visual project coordination is a central part of the Obeya concept ... "

Obeya visual controls were used to develop the Prius.

Fiat sees Advanced Lean Manufacturing Plants

Chrysler Canadian plants show well, with regards to their lean practices. ...

... "We know that Fiat officials who toured our plants were often quite complimentary and quite surprised at how advanced we were in lean manufacturing. " ...

Via Canada dot com: Fiat CEO

Volkswagen Chattanooga Lean Manufacturing Training

Volkswagen invests in new manufacturing facility and preparing the workforce through training. The company collaborates with local institutions to create and deliver lean and other manufacturing education. ...

... "VW and Chattanooga State Technical Community College are working on training modules such as technology, quality control, leadership and lean manufacturing processes ... " ...

Via Chattanooga Times Free Press: VW

Toyota Kentucky Lean Manufacturing

Ford Flexible Manufacturing Showcased

Ford Louisville Kentucky manufacturing plant uses lean methods and flexible techniques to balance production across the product line. ...

... "The automaker is showing off the Chamberlain Lane plant's new lean manufacturing process, which the automaker estimates as a $200 million investment in flexible manufacturing. " ...

Via WHAS11, Louisville, Kentucky: Ford plant

In the past, the Kentucky-based plant was a candidate for restructuring. ...

Via Auto ChannelLouisville, KY Ford Plant: "The announcement Thursday marks a turnaround for the Louisville plants since 2006, when they were considered by Ford as candidates for closure. "

The Ford Motor Company discusses the transformation to flexible manufacturing at the Louisville site. ...

Via Ford: FLEXIBLE MANUFACTURING BEGINS AT FORD KENTUCKY: "The heart of Ford’s manufacturing transformation is based on flexible operations, using reprogrammable tooling in body shops, standardized equipment in paint shops and a common-build sequence in final assembly, enabling production of multiple models in one plant. With standardization comes increased repeatability and improved ease of access, resulting in improved safety, ergonomics and quality. Kentucky Truck added a second trim shop as well as third shifts in the body, paint and stamping to handle the increased production. "

Cisco uses the Ford lean supply chain as an example of business integration in the automotive value chain. ...



Ford's commitment to lean extends to the supply chain. ...

Via Cisco: Auto-Xchange, a Ford/Oracle Joint Venture: "Auto-xchange: The Ford/Oracle venture announced in November 1999 brings the automotive community together via the Internet. It is an open network where the entire automotive supply chain will benefit from online procurement and trading, real-time supply chain management and collaborative product innovation. "

Lean Proactive Business Model

New Zealand manufacturer sees strong productivity benefits from lean manufacturing. The workforce culture has been transformed to one that contributes ideas freely to proactively improve the process. ...

... "Also known by its Japanese term Kaizen, which means continuous improvement, Mr Cook said lean manufacturing had transformed his business from a reactive organisation to a proactive one working daily to improve itself and meant it took Stainless Design about half the time it used to to process work. " ...

Via Stuff.co.nz: Model T

Stainless Design Workforce Training Program: "Everyone in the company is, and has been, involved in training in Lean principles and implementing improvement projects throughout the business. All these projects will provide significant operational and business performance improvements. "

Peugeot Robotics in Manufacturing

Ford Production System Based on Lean Principles

Ford invests in new worker training and emphasizes lean thinking in the curriculum. ...

... "Workers new to the Dearborn plant spent the first two days of training focused on the Ford Production System and lean manufacturing principles, Pijor said. " ...

Via IndustryWeek: Ford Quality Training

Ford Six Sigma QOS Quality Operating System

Ford, where quality is not typically job one (my wife's Windstar check engine light was on for a decade), is seeing some success from Six Sigma improvement methods that reduce variation. The company packages its methods into a management system, or QOS. The critical to quality (CTQ) variables are monitored to drive customer satisfaction. ...

... "Ford also provides assembly plant teams the necessary tools to deliver quality in the manufacturing process. For example, the company’s Quality Operating System (QOS) is critical for identifying and correcting problems within the manufacturing facilities. QOS is implemented in each plant by Variability Reduction Teams (VRT) – cross-functional groups of engineers, plant management and product specialists, including the company’s most skilled problem solvers who’ve been trained through Six Sigma. Each team is assigned to one of 12 vehicle subsystems crucial to customer satisfaction, such as paint or body interior, and examines every detail, looking for imperfections so slight that even the untrained eye, or ear, could not detect them. " ...

Via Ford: Warranty Repairs Costs Decline

Lexus Hybrid RX Improves with Kaizen

New Lexus hybrid vehicle incorporates efficiency and performance updates enabled through the deployment of kaizen techniques throughout the design, development, and manufacturing processes. ...

... "The Lexus Hybrid Drive in the new RX is a perfect example of how Lexus uses kaizen to improve its vehicles, said Lexus Vice President and General Manager Mark Templin ... " ...

Via The FINANCIAL: Lexus Hybrid Drive

Honda Production Cuts

Honda idles its manufacturing footprint in North America to deal with the supply and demand imbalance. ...

... "Ed Miller, said the cuts would take place at five of Honda’s seven plants in the United States and Canada. Employees at the plants will be given other tasks or can take paid or unpaid vacation time ... " ...

Via NYTimes: Honda Production in North America

Flexible Shops with Lean Techniques Can Be Competitive

Ford CEO makes case for the industry and discusses the company's manufacturing flexibility. Ford is fixing the fundamentals of its business model, taking out fixed costs. ...

... "Our new products will be assembled in plants featuring lean manufacturing techniques, and, in nearly all facilities, flexible body shops will make them competitive with the best in the business. " ...

Via Detroit Free Press: Ford CEO testimony

Flexible Manufacturing with Efficient Parts Consolidation

New Honda facility in Indiana incorporates flexible manufacturing and efficiency capabilities on day one. ...

... "Yuzo Uenohara, president of Honda Manufacturing of Indiana, was joined in driving the first Honda Civic off the HMIN assembly line by three Honda associates: Daphna Tubbs of Greensburg, Willard Jones of Indianapolis, and Pam Manis of Sunman. The Greensburg facility reflects Honda's growing reputation for flexible and efficient auto manufacturing. It is Honda's fifth U.S. plant designed as a zero waste-to-landfill facility and will be the first Honda facility to feature an on-site parts consolidation center that is helping increase efficiency while reducing vehicle emissions and costs related to transportation and parts handling. " ...

Via Honda: Indiana Auto Plant

Real-Time Performance Monitoring

SAP automotive industry solution plays role in support of Vodafone McLaren Mercedes race team's Lewis Hamilton victory in the Brazilian Grand Prix. ...

... "During the 18 race season, the technology maintained information on the V8 engines of the Vodafone McLaren Mercedes 2008 cars, enabling the team to be fully alert to the performance of the cars’ engines. The win makes Hamilton Formula One’s youngest champion to date. Cutting-edge computer technology is playing an ever more crucial role in the world of car racing, as the slightest change can result in dramatic performance effects. " ...

Via SAP: Vodafone McLaren Mercedes Team Formula One Victory

Chrysler Quality: Job None

Chrysler is not likely to survive this economic downturn and suffers from a quality management foundation. ...

... "Chrysler nevertheless failed to make good on Mr. Zetsche's vow, despite a considerable amount of effort to improve operations on the factory floor. " ...

Via Wall Street Journal: Chrysler Poor Quality

Via The Scoop at Chrysler Group: CEO Bob Nardelli on Future: "As we rebuild confidence in the New Chrysler, we must also recognize that many outsiders and critics of our company are not yet aware of the steady strides we have made and the reasons we are optimistic about our future. "

Kaizen Culture

Experts from PPG Automotive Refinishing division will discuss kaizen and workforce culture at NACE session. ...

... "Kaizen Management: Building a Continuous Improvement Culture ... " ...

Via NACE 2008: Kaizen Session

Automotive Supplier Six Sigma

A group of UK automotive suppliers collaborate to learn and adopt Six Sigma methodology. Benefits achieved enable the development of new business. ...

... "She said that 16 people had now been certified as Six Sigma Green Belts and they would go back into their respective companies and implement what they had learned. " ...

Via Birmingham Post: New business through Six Sigma

Six Sigma Research and Development

Dow executive will bring Six Sigma experience to research and development leadership position. ...

... "Effective immediately, Dr. Bem will be responsible for identifying, developing and commercializing new technologies that create sustainable value. Dr. Bem is a certified Six Sigma black belt and holds nine US patents. He has authored more than 20 publications. He earned a Ph.D. in solid state inorganic chemistry from the Massachusetts Institute of Technology and his undergraduate degree in chemistry from West Virginia University. " ...

Via Dow Automotive: New Global R&D Director

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.

Six Sigma Internal Efficiencies: Sequa Corp.

Sequa automotive division shows improved performance through Six Sigma internal efficiencies ...

... "The two operations that make up the segment - ARC Automotive and Casco Products - serve a global market, providing airbag inflators and electronic sensors, power outlets and cigarette lighters. Results of these businesses, which reflect the restrictive conditions affecting the overall automotive market, were mixed for 2005. ARC generated modestly increased sales, though profits were curtailed by higher steel surcharges and new plant start-up costs, the latter related to the opening of new facilities in Mexico and China. After the close of the year, ARC transferred production from a plant in Arkansas and released 300 employees, a move that will lead to a redundancy provision in the first quarter of 2006. Casco Products posted a five percent sales gain, chiefly at operations in Europe and Latin America, and improved profits, the latter due largely to internal efficiencies and cost savings created through ongoing Six Sigma initiatives. " ...

Six Sigma Internal Efficiencies: Via Sequa Corp.: Sequa Posts Sharply Higher Operating Results for 2005 ...

Manufacturing Excellence Recognized: Shingo Prize ...

Autoliv production system recognized for manufacturing excellence, with the Shingo Prize. ...

... "Autoliv Inc. – the worldwide leader in automotive safety – announced that its Promontory Facility in Utah has received the 2006 Shingo Prize for Excellence in Manufacturing.

Through the application of the Autoliv Production System, the facility has reduced process lead time by 69%, reduced customer ppm to zero, increased production efficiency to 99%, reduced inventory by 68%, reduced overhead by 38% and improved LMPU by 45%. During this same time, the Autoliv Promontory Facility has received numerous awards for outstanding safety and environmental practices. Some of those practices include developing a process to disassociate explosives back into their constituent raw materials. By using this process, the facility has not only recovered copper to sell on the open market, but has also eliminated over 150,000 lbs. of hazardous waste per year from being burned. " ...

Manufacturing Excellence Recognized: Shingo Prize: Autoliv Promontory Facility Receives Shingo Prize for Excellence in Manufacturing ...

Lean Manufacturing Streamlines Workflow and Repair Operations ...

Metro Toyota embraces lean manufacturing principles in its repair operations to streamline the workflow ...

... "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 ... " ...

Lean Manufacturing Streamlines Workflow and Repair Operations: Via ABRN (Automotive Body Repair News: Metro Toyota grabs top Toyota certification for new collision repair center ...

SixSigma Efficiency Model in the British Automotive Industry ...

Terry Murden explores the methods of Stuart Ross, a veteran of Six Sigma and Kaizen ...

... "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. " ...

SixSigma Efficiency Model in the British Automotive Industry: Via Scotsman Business: The man who would save Scottish industry ...

Solectron LeanSixSigma Enables AS9100 Certification ...

Solectron leverages its Lean Six Sigma discipline to enable AS9100 quality certification ...

... "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. " ...

Solectron LeanSixSigma Enables AS9100 Certification: Via Solectron: Solectron Announces Successful Aerospace Manufacturing Certification to AS9100 Rev B ...

Executive and Manager Overview: ISO 9001:2000/AS9100 Rev. B: "ISO Joe's Executive and Manager Overview: ISO 9001:2000/AS9100 Rev. B provides and expands uponthat foundational knowledge, and examines and compares today's commonly used quality programs and systems. "

Six Sigma GreenBelt Program Engineer ...

Program engineer position wih Six Sigma green belt experience ...

... "Serves as Primary contact for Account Managers & Program Engineers at the Corporate level. Specify In-house & Vendor Tooling; Track Process & participate in Run-Off; Set up initial Process Flow & BOM Router; Quote new processes and equipment; Product Launch Documentation, Process Flows, Tooling Specs, Packaging Specs, Internal & External Tooling; FEMA's Time Studies. Provide expert leadership in coordinating, facilitating, motivating & directing team efforts of a cross-functional program team. This position requires a BSME or other 4 year engineering degree and minimum of 2 years experience in the automotive industry. Six Sigma Greenbelt status preferred. Knowledge of automotive industry systems such as TS 16949 & ISO 14001. " ...

Six Sigma GreenBelt Program Engineer: Via TOP JOBS OF THE TRI-CITIES ...

Lean Six Sigma Maintains Tenneco Margins ...

Tenneco maintains its profit margins with help from Lean Six Sigma programs ...

... "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. " ...

Lean Six Sigma Maintains Tenneco Margins: Via Tenneco: TENNECO REPORTS SOLID FOURTH QUARTER EARNINGS AND STRONG OPERATING CASH FLOW: Company Forecasts $1 Billion in OE Business Growth in 2007 ...

Tenneco is a $4.4 billion manufacturing company with headquarters in Lake Forest, Illinois and approximately 19,000 employees worldwide. Tenneco is one of the world's largest designers, manufacturers and marketers of emission control and ride control products and systems for the automotive original equipment market and the aftermarket. Tenneco markets its products principally under the Monroe, Walker, Gillet and Clevite Elastomer brand names. Among its products are Sensa-Trac and Monroe Reflex shocks and struts, Rancho shock absorbers, Walker Quiet-Flow mufflers, Dynomax performance exhaust products, and Clevite Elastomer noise, vibration and harshness control components.

Lean Automotive Production Manager ...

... "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. " ...

Lean Automotive Production Manager: Via jobs.telegraph.co.uk ...

Lean Manufacturing: Ford Continues Transformation ...

Ford made early progress on lean manufacturing, emulating Toyota's quality success, however market shifts continue. Isaac Cheifetz explores the challenges of the automotive industry to adapt to market forces and balance short-term profitability with long-term organizational design, as Ford announces its restructuring transformation. ...

... "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. " ...

Lean Manufacturing: Ford Continues Transformation: Via Minneapolis-St.Paul Star-Tribune: Focus on short term hurt U.S. carmakers ...

Kaizen Automotive: Speed and Flexibility ...

Kaizen is not enough to be competitive in the global automotive industry today. Speed and flexibility are critical success factors. ...

... "He said the industry used to talk about kaizen, or continuous improvement. But that's no longer enough to survive in today's environment, he said. " ...

Kaizen Automotive: Speed and Flexibility: Via Automotive News: Suppliers stress vital need to be fast and flexible ...

Kanban: Software Enables Lean Flow ...

Glovia International, Fujitsu subsidiary, introduces additional Electronic Kanban (eKanban) functionality, that enable manufacturers to have greater control and flexibility over managing inventory levels as well as the ability to establish triggers to automatically replenish inventory when predefined minimums for each inventory level have been reached. ...

... "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. " ...

Kanban: Software Enables Lean Flow: Via Glovia : FUJITSU: Glovia Expands Electronic Kanban Functionality: Product Enhancements Provide Greater Control of Automatic Materials and Inventory Replenishment ...

Lean Manufacturing: Software Enables Waste Reduction ...

Oracle software enables lean manufacturing transformation at Asia automotive parts manufacturer. ...

... "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. " ...

Lean Manufacturing: Software Enables Waste Reduction: Fastest-Growing Automotive Parts Company in Thailand Implements Oracle E-Business Suite to Enable Lean Manufacturing: Company Moves to Lean Manufacturing To Eliminate Waste and Reduce Risk in the Supply Chain for Thai, Malaysian and Chinese Facilities ...

VP Operations: Lean Manufacturing Career ...

VP operations has career path in lean manufacturing. ...

... "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. " ...

VP Operations: Lean Manufacturing Career: Via Tower Automotive: Craig Corrington Joins Tower Automotive As Vice President of Operations for North America

Lean Program: GROWTTH ...

Dr. Mohsen Sohi, president and chief executive officer of Freudenberg-NOK, was named to the board of directors of the Original Equipment Suppliers Association (OESA). He is executive champion of the lean program, GROWTTH. ...

... "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. " ...

Lean Program: GROWTTH: Via Freudenberg-NOK: Freudenberg-NOK President & CEO Named to OESA Board of Directors ...

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 ... "

Automotive Lean Manufacturing Focus

Automotive industry still needs to focus on lean manufacturing to sustain its competitiveness. In addition, internet buying is shifting the dynamics to a make-to-order model. ...

... "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. " ...

Via IndyStar: U.S. auto's bumpy road ...

SixSigma OpExcellence Exec Appointed President ...

Six Sigma Operational Excellence executive is appointed president. ...

... "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. " ...

SixSigma OpExcellence Exec Appointed President: Via Crane Co.: Crane Co. Appoints David Bender, President of Electronics Group ...

Lean Manufacturing: Production Area Manager Position Open ...

... "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. " ...

Lean Manufacturing: Production Area Manager Position Open: Via icWales - Hot Jobs - Production Area Manager ...

Supply Chain eHubs: Supplier Relationship Management ...

E2Open is growing its customer base for supply chain e-hubs, enabling supplier relationship management through a software-as-a-service SAAS delivery model. ...

Supply Chain eHubs: Supplier Relationship Management: Via E2open: E2open Leads Supply Chain-SRM SaaS Market, Deploying and Operating More Systems Than Any Other Company ...

... "E2open currently powers over 50 supply chain information hubs, sometimes referred to as eHubs, for leading companies in the electronics, aerospace and defense, and automotive industries, connecting more than 12,000 trading partners and 45,000 users. The supply chain-SRM market addresses both internal and external processes. Internal processes such as advanced planning and scheduling, demand shaping and factory optimization have been the realm of traditional on-premises enterprise software. There is growing evidence that external processes that give visibility and control over extended supply networks, such as vendor-managed inventory, supply-demand synchronization and procure-to-pay, can be managed more cost- and time-effectively and with higher data quality by inter-enterprise software in a SaaS model. AMR Research describes this concept as inter-enterprise services. " ...