Manufacturing Supply Chain Integration

Ford supply chain integration reviewed ...

SixSigma Enables Unified Communications Cost Efficient Service For Ford

Getronics receives contract with Ford to install, deploy, and manage a voicemail, audio conferencing, and web collaboration solution that is based on the Cisco Unified Communications solution. ...

... "Getronics' dedication to the Six Sigma methodology, a disciplined approach to quality that drives cost efficiency in service delivery, will play a key role in the implementation. The new unified communications solution delivered and managed by Getronics will enable a year over year savings, while consolidating Ford's technology infrastructure onto a single networking infrastructure. " ...

Via Getronics: Unified Communications For Ford Motor Company

Lean Automotive Is Relevant Today As 17 Years Ago

Lean manufacturing principles are as relevant today, as when introduced years ago. Ford, GM, Chrysler need a refresher course. ...

... " ... it seems fitting that The Machine That Changed the World, the seminal 1990 book on lean manufacturing as practiced by Toyota Motor Corp., is now being reissued. " ...

Via Detroit Free Press: Automotive Challenge

Lean Discipline: Mulally Recognized

Leader Alan R. Mulally is recognized for his role is changing the fortunes of American manufacturing icons. ...

... "His zeal for management - the relentless focus on planning, production and embracing everyone as a team member - has gone well beyond the disciplines of lean manufacturing and continuous product improvement. " ...

Via Aviation Week and Space Technology: Person of the Year

Lean Flow Sheds Waste ...

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

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

Via Public CIO: Trimming Waste Fast

Six Sigma Opportunity Software ...

Software prioritizes Six Sigma project opportunities by financial benefit by collecting data from plant systems. ...

... "Hagen & Co., a leading provider of software and services for manufacturing and process improvement, has introduced True Opportunity software – the world's first dollar-based manufacturing performance reporting system. True Opportunity software is ideal for Overall Equipment Effectiveness (OEE), Six Sigma, and Lean Manufacturing applications and is the only solution that calculates the true profit potential of an organization's manufacturing operations. In addition, the solution also breaks down this total extra profit opportunity by reason, allowing an organization to focus on the problems or opportunities that will realize the greatest results. " ...

Via Hagen: Hagen Introduces True Opportunity Dollar-Based Software For Six Sigma, OEE, & Lean Applications

Mulally Lean Experience Ford's Benefit ...

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

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

Via Economist: Ford's new pilot ...

Jaguar Lean Revamp Drives Efficient Production ...

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

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

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

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 ...

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 ...

RFID Company Lean Manufacturing Value ...

RFID Company Lean Manufacturing Value: Wherenet: WHERENET SALUTED AS A HOT COMPANY BY START MAGAZINE FOR THE SECOND STRAIGHT YEAR: Inbound Logistics and Supply & Demand Chain Executive Magazines Also Recognize WhereNet for Driving Innovation and a Strong Return on Investment for Global Customers Leveraging the Company’s Active RFID-Based Real-Time Locating System Technology ...

... "WhereNet stands out as a market leader because its active RFID technology has been commercially deployed and has delivered proven business value for more than five years, said John Buell, editor-in-chief of Start magazine. WhereNet's applications are transforming business processes and driving new lean manufacturing principles for leading manufacturers around the world. " ...

WhereNet is the first company to deliver a single wireless location and communication infrastructure that reliably and cost-effectively manages valuable mobile resources and delivers a complete return on investment within 6-12 months. Based on patented, standards-compliant technology resulting from a collective 100+ years of development, the WhereNet real-time solutions enable companies such as BMW, Ford Motor Company, and NYK Logistics to reduce inventory, lower operating costs, and improve operations. The company has received the Henry Ford Technology Award; was recognized for strong ROI by Computerworld; was ranked among the top 10 in the InfoWorld 100; and has been recognized as a wireless innovator by Forrester Research, Computerworld ROI, Frontline Solutions, Plant Engineering, and Supply Chain Systems magazines. Headquartered in Santa Clara, California, with offices throughout the United States and Europe, WhereNet is funded by Crosspoint Venture Partners, Foundation Capital, Bay Partners, Crescendo Ventures, and Sun Microsystems.

Lean Manufacturing Centre Excellence ...

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

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

Ford Lean Manufacturing Career Moves ...

St. Paul Pioneer Press | PUBLIC COMPANY NEWS

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

Supply-Side Lean Manufacturing Techniques by Ford ...

Chicago Tribune | U.S. auto industry takes a stand: James P. Miller, Chicago Tribune reports that Ford Motor implemented a $400 million lean manufacturing tranformation of a flexible production plant with an inbound supplier facility. This cluster configuration for suppliers drives versatility and lowers cost, such as operational logistics and transportation.

Ford Lean Manufacturing Gets Flexible ...

i-Newswire.com - Press Release And News Distribution - Ford Motor Company�s Michigan Truck Plant Body Shop Now Features Flexible Manufacturing

From i-Newswire.com - Ford Motor Company's Michigan Truck Plant Body Shop Now Features Flexible Manufacturing ...

... "Our goal is to build stability and standardization into our North American assembly and stamping plants, which is what flexible and lean manufacturing is all about.' said Matt DeMars, Ford vice president, Vehicle Operations. The Truck Plant produces the Ford Expedition and Lincoln Navigator. This particular plant employs more than 3,000 hourly employees. The addition of the flexible body plant will certainly expand the production capabilities of the plant. " ...

Toyota Production and Lean Manufacturing History: Ford is considered by many to be the first practitioner of Just In Time and Lean Manufacturing. Ford's success inspired many others to copy his methods. ...

Lean Manufacturing and Lean Enterprise: Henry Ford, in fact, systemized lean manufacturing during the early 20th century--- and the Japanese read his books thoroughly and ardently. ...

Henry Ford's Lean Vision: excerpts from the Introduction: Earlier scientific management practitioners like Taylor and Gilbreth laid the foundations of what we now call lean manufacturing; Ford systematized it on an ...

Lean Manufacturing: Ford expected these changes to reduce hood defects by 97 percent and save $283,000 a year. The Lean & Six Sigma advantage. Lean Manufacturing and Six Sigma have ...

Lean Manufacturing Implementation Career Path ...

Lean Manufacturing Implementation Career: Donaldson Company Names Jay Ward As Managing Director Of Donaldson ...

From Yahoo News (press release) ... "Jay's leadership in productivity improvements, lean manufacturing implementation and customer focus initiatives provides him with a great background for ...

... Donaldson Company, Inc. (NYSE: DCI - News), today announced that it has appointed Jay L. Ward as Managing Director of Donaldson Europe, effective February 1. Most recently, Ward was Director of Product Management for Donaldson's Industrial Filtration Solutions Group. ...

Donaldson Company, Inc., headquartered in Minneapolis, is a leading worldwide provider of filtration systems and replacement parts. Founded in 1915, Donaldson is a technology-driven company committed to satisfying customer needs for filtration solutions through innovative research and development. Donaldson serves customers in the industrial and engine markets including in-plant air cleaning, compressed air and gas purification, power generation, specialty filtration, off-road equipment and trucks. Our 10,000 employees contribute to the company's success at over 30 manufacturing locations around the world. In fiscal year 2004, Donaldson reported sales of more than $1.4 billion and grew earnings for the 15th consecutive year. Donaldson is a member of the S&P MidCap 400 Index and Donaldson shares are traded on the New York Stock Exchange under the symbol DCI.

Additional resources on a lean manufacturing implementation career ...

A Synergistic Approach to Minimizing Waste: Ford, who began his career as a mechanic, lacked ... This lean manufacturing concept follows the chapters on TOC and ... identify the constraint, or longest path, in a ...

Lean Aircraft Initiative Implementation Workshop: Implementing: File Format: PDF/Adobe Acrobat ... one of the key elements of lean production – effort spent ... of flight without redesign or manufacturing changes ... function and a viable management career path. ...

lean manufacturing management software: Factory Logic has the career path for you ... good people for software development and implementation consulting roles ... the true potential of lean production is built ...

Six Sigma and Lean Manufacturing: Lean Production Implementation Roadmap PDF file detailing the ... are organizational infrastructure, career path/ incentives ... like a lean manufacturing expert in no ...

Six Sigma Automotive Suppliers Make Progress ...

Six Sigma Automotive Suppliers: We must be proud of the new breed ...

From ic Birmingham.co.uk, UK ... "Technology has also been another key driver, with suppliers clearly recognising the need to embrace six-sigma, high voltage systems and the latest ...

Accelerated six sigma applications by automotive suppliers ...

Best Practice in Tier 1 Automotive Manufacturing: File Format: PDF/Adobe Acrobat ... In 1986, 30,000 automotive suppliers competed in a $250 ... of data a month enables six sigma and continuous ... Automation suppliers generally lack solutions that can ...

Autoliv - Quality: Applying the corporate-wide Six Sigma initiative, which was started in 2001 ... the car manufacturers, quality is a competitive tool for many automotive suppliers. ...

Automotive industry trends demand Lean Manufacturing and Six Sigma: File Format: PDF/Adobe Acrobat ... Automotive suppliers need to move quickly to insure survival. ... DeKoker strongly advises that firms focus on Lean Manufacturing and Six Sigma. ...

Six Sigma workshops to aid West Midlands firms: automotive companies based upon a series of Six Sigma key objectives and selected projects. This will be targeted to up to 10 SME automotive suppliers in the ...

Chinese Automotive Boom: in Shanghai and spent a year teaching Six Sigma methods to Chinese automotive officials. ... Suppliers, including a growing number of American companies, are ...

Six Sigma to save Ford $300 million: Vitec courts minority suppliers Compiled by Senior Editor ... Compiled by the staff of WARD'S AUTOMOTIVE REPORTS. Six Sigma to save Ford $300 million Compiled by ...

Lean Manufacturing Could Improve Performance at Nine More Sites ...

From ITP: Fourth Round of Plant-Wide Assessments ...

... "Ford Motor Company, Cleveland, Ohio, will address the production process and will apply the principles of lean manufacturing to identify energy and cost reductions in the manufacturing operation. Formosa Plastics, Port Comfort, Texas, and its partners will conduct a plant-wide study to develop and implement methods and strategies that address energy efficiency, waste reduction, productivity, and global competitiveness. Georgia Pacific, Crossett, Arkansas, developed a plan to evaluate the plant as an integrated entity to achieve system-wide gains. The plant will use computer-modeling tools to verify mill data and perform system-wide optimization. Jernberg Industries, Chicago, Illinois, will apply lean manufacturing principles and identify waste stream and productivity opportunities that can save energy. North Star Steel, Wilton, Iowa, will focus on energy, waste, and productivity and will initiate a total assessment audit to identify opportunities in the manufacturing systems facility." ...

Lean Value Stream: Resource Management

From Robins Air Force Base, Air Force Materiel Command ...

... "By 1950, the Japanese, who greatly admired Henry Ford, established the Toyota Production system that began to eliminate waste from the process. In the 1970s, the Japanese continued to implement American principles by Juran, Deming, Shewhart, and Crosby at Toyota. By 1980s, Americans took notice of the loss of market share of automobiles, shipbuilding, electronics, avionics, office equipment, etc., and embraced Quality. By the late 1980s, Toyota had nearly achieved Lean. Over the years, the Air Force explored various programs such as Zero Defects, Meaningful Measures of Merit, Total Quality Management, and QP4 in an effort to streamline processes and eliminate waste. By 1990, the focus became Lean Principles with the establishment of five principles: Value, Value Stream, Flow, Pull, and Perfection. By 2000, Lean was used in Production, Services and Remanufacturing. With Lean, the customer determined the first principle to be value, based on cost, quality, and delivery. " ...

Robins Air Force Base, home of Warner Robins Air Logistics Center and more than 60 other units that make up a vital part of the Air Force war fighting team. It is the largest industrial complex in Georgia, employing a work force of over 25,584 civilian, contractor, and military members.

Kaizen Techniques: Lean Manufacturing and the Environment

From Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment ...

... "This shift requires highly controlled processes operated in a well maintained, ordered, and clean environment that incorporates principles of employee-involved, system-wide, continual improvement. Common methods used in lean manufacturing include: Kaizen; 5S; Total Productive Maintenance (TPM); Cellular Manufacturing; Just-in-Time Production; Six Sigma; Production Preparation Process (3P); and Lean Enterprise Supplier Networks." ...

The Council for Excellence in Government works to improve the performance of government at all levels; and government's place in the lives and esteem of American citizens. With its experienced staff, network of experts and members, and diverse partners, the Council helps to create stronger public sector leadership and management, driven by innovation and focused on results; and increased citizen confidence and participation in government, through better understanding of government and its role. The Council is supported by members (called Principals)---private sector and nonprofit leaders who have served in government and are united by a strong, sustaining commitment to Council objectives---and by project grants and other funding from government agencies, corporations and foundations. Former Presidents Carter, Ford, Bush and Clinton are honorary chairs of the Council.

Lean Manufacturing Career Path: Tower Automotive Hires Terry Gohl as Vice President of North ...

From Business Wire (press release), CA ... His expertise in implementing lean manufacturing systems and operational improvements will enhance our efforts to drive excellence throughout the organization. ...

... Tower Automotive, Inc. (NYSE:TWR) today announced that Terry Gohl, 43, has joined the company as vice president of North American operations, effective immediately. Gohl reports to Kathleen Ligocki, president and chief executive officer of Tower Automotive. ...

Tower Automotive, Inc., is a global designer and producer of vehicle structural components and assemblies used by every major automotive original equipment manufacturer, including BMW, DaimlerChrysler, Fiat, Ford, GM, Honda, Hyundai/Kia, Nissan, Toyota, Volkswagen and Volvo. Products include body structures and assemblies, lower vehicle frames and structures, chassis modules and systems, and suspension components.

Lean Manufacturing: DURA to Supply Ford with Floor Shifters on New Models

From Business Wire (press release), CA ... This design lends itself to lean manufacturing practices, significant labor cost reductions, and streamlined time-to-market for new programs. ...

... DURA Automotive Systems, Inc. (Nasdaq:DRRA) announced today it will supply a family of modular automatic floor shift systems to Ford Motor Company on several future car and light truck models. ...

DURA Automotive Systems, Inc. (Nasdaq:DRRA), is the world's largest independent designer and manufacturer of driver control systems and a leading global supplier of seating control systems, engineered assemblies, structural door modules and integrated glass systems for the global automotive industry. The company is also a leading supplier of similar products to the North American recreation and specialty vehicle markets. DURA sells its automotive products to every North American, Japanese and European original equipment manufacturer (OEM) and many leading Tier 1 automotive suppliers. DURA is based in Rochester Hills, Mich.

Lean Six Sigma Training: $7.2 million in state support for job training programs

From - 2004-10-26 - The Business Journal (Minneapolis/St. Paul) ...

... "The Ford Motor Company and St. Paul College received $399,305 for training in continuous improvement, lean manufacturing and Six Sigma for 2,085 employees at the St. Paul Ford plant. " ...

Relevent info on the Minnesota program ...

The purpose of the Minnesota Job Skills Partnership Program is to act as a catalyst between business and education in developing cooperative training projects that provide training for new jobs or retrain existing employees. Funds may be used for educational infrastructure improvements necessary to support businesses located or intending to locate in Minnesota. The combined allocation for Job Skills Partnership, Pathways, Hire Education Loan and Distance Work programs is $6.8 million per year from state funds.

Lean Production / Lean Manufacturing Videos: Womack Videos 1 and 2

From Defense Systems Management College ... James P. Womack is currently an author and an advisor to many firms seeking to adopt the principles and techniques of Lean manufacturing & business. Mr. Womack, while a professor at MIT, co-authored the book "The Machine that Changed the World", which introduced readers worldwide to the concepts of Lean manufacturing, as typified by the manufacturing management processes used by the Toyota automotive company. Mr. Womack also co-authored the book "Lean Thinking" which describes application of Lean principles outside manufacturing and outside the automobile industry.

... James Womack, then another IMVP researcher in the late 1980s, credits Henry Ford with developing the first "Lean" principles, in the second decade of the 20th century. Indeed, Taiichi Ohno, the father of the Toyota Production System, TPS-the embodiment of "Lean" principles-credits Ford with the inspiration for Toyota Motor Company to spend 50+ years developing their manufacturing techniques and management principles based upon what we now call "lean" ...

Six Sigma Success: Michigan Businesses Will 'Learn to Thrive' at Henry Ford Community ...

From PR Newswire (press release) ... Kaizen, Value Stream Mapping, Organizational Change, etc.), Lean Process Design (Administrative, Design, Engineering and Purchasing), Six Sigma and Performance ...

... On September 16, 2004, Henry Ford Community College (HFCC) is hosting a "Surviving to Thriving" event where executives from area businesses can gather with specialists from local agencies, and discover available resources that will vault their companies to the next level of success. ...

In October 1998 ITI changed its name to the Michigan Manufacturing Technology Center (MMTC). With ITI's consolidation of its operating units, and the organization now focused on the MMTC mission of helping small and midsize manufacturers, it was only natural to adopt the MMTC name. ITI's former business units now operate as one integrated organization called the MMTC dedicated to enhancing the global competitiveness of Michigan’s small and midsize manufacturers.
- Established in 1991 as a NIST-Manufacturing Technology Center to serve small and midsize manufacturers
- Offers Services specifically designed for small and midsize manufacturers with less than 1000 employees
- MMTC assistance projects are credited with more than $80.1 million in sales impact since 1999 and more than $32 million in cost reduction (Marketfacts survey results for projects closed 1/1999-6/30/2000)
- Rated as the number one provider of training services in ASQ/AIAG survey

Six Sigma Manufacturing Summit: Visteon Manufacturing Director to Speak at Annual Manufacturing ...

From Yahoo News (press release) ... "As a manufacturing director, it's my responsibility to employ established manufacturing strategies with Six Sigma and lean manufacturing practices," said ...

... Lou Whitlock, manufacturing director for the powertrain product line for Visteon Corporation (NYSE: VC - News), will speak at the Society of Manufacturing Engineers' (SME) 2004 Manufacturing Technology Summit on Aug. 11, 2004, in Detroit. Whitlock will share insight on Visteon's product, design and process development contributions that supported Ford Motor Company's successful launch of its new F-150 pickup truck. ...

Visteon Corporation is a leading full-service supplier that delivers consumer-driven technology solutions to automotive manufacturers worldwide and through multiple channels within the global automotive aftermarket. Visteon has approximately 72,000 employees and a global delivery system of more than 200 technical, manufacturing, sales and service facilities located in 25 countries.

Lean Manufacturing Career: Tower Automotive Hires Wenzl to Lead Global Human Resources and ...

From Business Wire (press release), CA ... Her broad experience base, along with expertise in implementing lean manufacturing systems, will help jump-start cultural change initiatives at Tower.". ...

Tower Automotive Inc. is a global designer and producer of vehicle structural components and assemblies used by every major vehicle manufacturer, including BMW, DaimlerChrysler, Fiat, Ford, General Motors, Honda, Hyundai/Kia, Nissan, Toyota and Volkswagen Group. Products include body structures and assemblies, lower vehicle frames and structures, chassis modules and systems, and suspension components. The company is based in Novi, Michigan.

Lean Manufacturing Software: Simulation delivers results for Ford

From AWKnowledge, United Kingdom ... line must never stop due to a shortage of components, they must also ensure that the line operates according to the company's lean manufacturing principles ...

Lean Six Sigma: Details keep A-dec lean

From Oregonian, OR ... called Lean. In the same way General Electric Co. became known for its Six Sigma program and Ford Motor Co. championed Total Quality ...

Lean Manufacturing: Lean manufacturing is a process whose time has come--with help from software vendors...

From Information Week ... Lean isn't a word that's generally associated with smoke-belching factories and mammoth manufacturing plants. But in some circles it is--more and more, these days. "Henry Ford used the word lean when referring to manufacturing," says Mike Mitsch, VP of operations at Keihin Aircon North America Inc., a company that has used lean-manufacturing techniques for nearly a decade to make heating, ventilating, and air-conditioning components for the automotive industry. "Lean has been around for years in different capacities, and now it's making a comeback." Mitsch is referring to the practice of lean manufacturing, a methodology that seeks to eliminate all waste from the manufacturing process ...

Oracle Solutions for Heavy Equipment and Machinery Manufacturing: Machinery and equipment manufacturers are trying to come to terms with declining sales and increased competition. Those manufacturers who hope to survive--and thrive--focus on improving business process efficiency, whether through adopting lean techniques or sharing services at facilities around the globe. Delivering a superior customer experience across all channels is critical when you have products that can be configured to customer need. Stand out from the crowd by making doing business with your company easy, leveraging your brand, and providing the end customer with timely and cost-effective solutions.

Lean Manufacturing: Trade, Terrorism discussed at candidates forum

From San Jose Mercury News, CA ... So anyone who is promising to bring back manufacturing jobs doesn't understand lean manufacturing continues quality improvement.". ...

...2004 Recipients of the 2004 Shingo Prize for Excellence in Manufacturing. Dubbed the "Nobel prize of Manufacturing" by Business Week, the Shingo Prize is increasingly being recognized as the premier manufacturing award and recognition program in North America. Nine state-level awards and a public-sector category, primarily for Military Depots doing re-manufacturing, have been implemented in recent months.

Three notable achievements of the 2004 recipients include: one, 7 of the 12 achieved product quality of less than 10 "returned parts per million opportunities" from the customer; two, 7 of the 12 have inventory turns of more than 25 per year (compared to a U.S. average of 8); and three, premium freight as a percent of production costs averaged 0.12 percent. These data cover the full-year of 2003 and are all clear indicators of world-class manufacturing achievements.

"Once again the recipients of the Shingo Prize demonstrate that they are prepared to weather economic uncertainty by not wasting precious manufacturing and business resources, "said Ross Robson, Shingo Prize executive director. "Shingo Prize recipients and lean manufacturers clearly stand out among the manufacturers of North America in terms of quality, cost, delivery and business results."

This year's Shingo Prize Recipients are:

ArvinMeritor Light Vehicle Systems Gladstone plant, Columbus, Ind. -- This facility proudly manufactures complete exhaust systems and components for today's leading car manufacturers. Through an engaged workforce of more than 700 people who are trained in lean principles, team building and employee involvement practices, substantial quality and productivity improvements have been made. Most notably, those improvements have included a decrease in customer PPMs of 72 percent since 2000, a decrease in supplier PPMs of 99 percent since 2000, a 54-percent decrease in the cost of non-quality since 2000, and an on-time delivery average of 99.9 percent since 1999.

Delphi Corporation, Delphi Electronics and Safety, Delnosa 5 & 6 Operations, Reynosa, Mexico -- Delnosa 5 & 6 manufactures over 24,000 vehicle electronics products daily for 72 customer locations in 11 countries for Delphi Corporation (NYSE: DPH - News). Delnosa's product line includes Audio, Mobile Multimedia, Telematics (interactive satellite technology), Navigation Radios, and Antenna Electronics. Delnosa also produces over 16 million molded and decorated plastic parts and assemblies each month that are used in Delphi facilities globally. In the last three years, Delnosa has increased productivity by 41%, increased inventory turns by 70%, improved first time quality by 76%, and increased asset utilization by 40%. Delnosa's 2,500 employees reached 200% participation in the employee suggestion program in 2003 and have currently worked over 22 million hours without a lost workday accident.

Delphi Electronics & Safety, Kokomo Operations, Plants 7 & 9, Kokomo, Indiana -- Kokomo Operations, Plants 7 & 9 is a vehicle electronics manufacturing facility employing over 1,100 people. These employees, represented by UAW Local 292, produce approximately 12 million units annually across four major product lines: audio components, power train controllers, inflatable restraint system electronics and electronic climate controllers. Applying the lean manufacturing concepts in the Delphi Manufacturing System, the facility has been able to achieve a third straight year of double-digit manufacturing performance, a 24% reduction in inventory, a 51% improvement in first time quality and has reached an annual shipping compliance rate approaching 100%.

Delphi Corporation, Energy & Chassis Systems, Empresas Ca-Le de Tlaxcala, Mexico -- Ca-Le is a battery manufacturing plant of 1,291,669 square feet, founded in February 1990 and located in Tetla, Tlaxcala, Mexico. Operating in a world-wide market, CALE produces two different automotive battery technologies: Hybrid (Antimony -- Calcium) and Maintenance-Free (Calcium-Calcium). Our productive headcount of 575 persons -- through the implementation of lean concepts and techniques -- work daily on EXCEEDING OUR CUSTOMERS' EXPECTATIONS. Our business results, customer satisfaction and quality of our products reflect our commitment with our employees, society and stakeholders.

Delphi Sistemas de Energia S.A. de C.V., Plt. 57; Chihuahua, Chihuahua Mexico -- Located in Chihuahua, Chihuahua Mexico since 1986 and serving 55 customers in 12 countries, Delphi Sistemas de Energia is a top of the line manufacturing organization. Here the combination of people who love their jobs, together with strong leadership, applying continuous learning and lean concepts, along with variation reduction, and defect prevention methods, have all contributed to superior satisfaction levels for customers, stakeholders and employees, creating a positive impact to the community and to the global environment.

Delphi Corporation, Packard Electric Systems. Plant 50, Del Parral Chihuahua, Mexico

Delphi's Packard Electric facility opened in February of 1998 in Hidalgo del Parral (more commonly referred to as Parral) in the southern part of Chihuahua, Mexico. The plant has 141,575 square feet of manufacturing floor space and 2,200 employees. These dedicated employees manufacture 13 families of products in 18 production lines, for 10 different General Motors assembly plants. The Parral plant produces power and signal distribution systems for the automotive industry, more commonly known as wiring harnesses. The motto at this facility is "Our people make the difference." Managers and supervisors say empowering employees and giving them opportunities make things happen. The success of this Delphi facility is attributed to its people.

Delphi Corporation, Packard Electric Systems. Plant 58, Meoqui, Chih. Mexico

The Meoqui Plant is located in the state of Chihuahua, Mexico and has been a part of Delphi Packard Electric's manufacturing footprint since 1987. The 1,800 employees at the 151,000-square-foot facility produce more than three million of wiring systems annually for several General Motors assembly plants in the United States and Canada. Employee commitment and a comprehensive implementation of the Lean-driven concepts within the Delphi Manufacturing System (DMS) have been able to drive operational improvements in cost, quality, delivery and productivity. Some of those improvements include: 20% reduction in customer complaints in 2003; 17% improvement in total cost compared to 2002; scrap reduction of 50% since 2000; first-time quality improvement 72% since 2001; and productivity increase of 35% compared to 2000.

Delphi Packard, Plant 98

Delphi Corporation, Packard Electric Systems, Centro Tecnico Herramental S.A de C.V, Ramos Arizpe, Coahuila.

With a wide variety of products and processes, CENTEC employees are flexible and skillful in successfully delivering parts to nearly 40 customers around the world. The majority of customers are in the US and Mexico, but several are also located in Europe, South America and Asia. The Delphi Manufacturing system drives the 470 CENTEC employees to continuous lean improvements. Elimination of waste, a 75-percent reduction in scrap and the Industria Limpia certification from the Mexican government for being environmentally sound are all part of the accomplishments of which CENTEC employees are very proud. Employees assemble wiring harnesses and their components and electric and electronic connectors. CENTEC now has a 0 IPM (incidents per million) on-time shipping record and have seen FTQ improve 87 percent since 1999. Continuous training of employees at all levels in daily skills and in lean implementation has led to the high quality at CENTEC.

Delphi Packard, Plant 51, Nuevo Casas Grandes Chihuahua, Mexico

Located in the PAQUIME area in the Mexican state of Chihuahua, Nuevo Casas Grandes began operations in March 1985. With strong customer-focused strategies and lean-driven concepts, this 165,000-square-foot plant builds and ships approximately 10,000,000 wiring systems annually to several General Motors vehicle assembly plants in the United States and Canada. The Casas Grandes Plant, which carries the slogan "The Best Plant by its People," has utilized the lean principles within the Delphi Manufacturing System to become one of the most successful plants in Delphi Packard's Mexico West Operations, with zero lost work days, over 80% reduction in RPPM (Rejected Parts Per Million), more than 50% reduction in Customer Complains, and 20% reduction in cost per shipped hour.

Maytag Jackson Dishwashing Products, Jackson, Tenn. -- Maytag Corporation's dishwasher plant is the first appliance manufacturer to earn the Shingo Prize. Associates belong to empowered High Performance Work Teams producing more than 100 dishwasher models daily, with brands including Maytag®, Jenn-Air® and Amana®. The Maytag LeanSigma® philosophy, which combines lean manufacturing methods with Six Sigma tools, was the path for transformation that began in 1999 and achieved significant improvements in Safety, Quality, Cost and Delivery, including a 64% reduction in OSHA recordable injury rate and 84% improvement in first pass quality yield. A very flexible single assembly line with capability to produce "any model/any day" was transformed into 8 single-piece-flow assembly cells with ability to produce "any model/any hour."

Raytheon Missile Systems, Tucson Operations, Tucson, Ariz. -- The employees at Raytheon Missile Systems proudly equip U.S. and allied warfighters with the latest technology to protect world freedom, including the Tomahawk Cruise Missile and Paveway(TM) laser guided bomb. Many of the company's products saw extensive use in Operation Iraqi Freedom. Raytheon's lean efforts have resulted in significant value improvements in product performance, stronger relationships and robust solutions for customers. Raytheon is committed to continue this journey to become a lean enterprise -- with speed, reliability and affordability -- and receiving the Shingo Prize has validated the firm's progress along the path to improvement.

TI Automotive, Cartersville, GA -- The plant produces more than 7.4 million brake and fuel bundles for Ford Motor Co. and DaimlerChrysler's Mercedes-Benz plants in both the United States and Canada. Cartersville team members operate by TI Automotive's own lean system of Common Sense Manufacturing, which is a passionate belief that there is always a simpler, better way. The plant has achieved single-digit ppm, 100 percent on time delivery and a 30 percent reduction in inventory levels. As the world's leading supplier of fluid storage, transfer and delivery systems, TI Automotive's more than 20,000 employees at 130 facilities worldwide are all dedicated to continuous improvement and customer satisfaction.

Finalists

In addition to the Recipients listed, other finalists included Aspect Medical Systems, Newton, MA.; Delphi Lansing Cockpit Plant, Lansing, Mich.; Delphi Energy & Chassis, Saginaw, MI; Delphi Steering Plant 7, Saginaw, Mich.; GDX Automotive, Vehicle Sealing Products, Batesville, AR; GDX Automotive, New Haven, MO; Maytag-Searcy Laundry Products, Searcy, AR; Nemak Corporation of Canada-Windsor Aluminum Plant, Windsor, Ontario, Canada; TI Automotive, Brake Tube Assemblies, Greenville, TN. "Each of these plants are also outstanding in their manufacturing processes," according to Robson.

The Shingo Prize for Excellence in Manufacturing, for manufacturers in the U.S., Canada and Mexico, is administered by the College of Business, Utah State University. Awards for the Recipients and Finalists will be presented at the 16th Annual Shingo Prize Conference and Awards Ceremony to be held May 20, 2004, at the Lexington Convention Center, Lexington, KY. Speakers will include Gary Convis, President, Toyota Motor, Georgetown, KY and Masaaki Imai, Founder and Chairman, Kaizen, Institute, Tokyo, Japan, among others. For more information, go to www.shingoprize.org.