Boeing ReThinks Manufacturing Outsource on Dreamliner

Boeing rethinks its outsourcing strategy after continuing delays with the manufacturing of its Dreamliner aircraft. ...

... "The reverberating effects of Boeing’s outsourcing missteps have taken a huge toll. The Dreamliner — the first passenger plane to be made mainly with light plastic composites — is now more than two years late ... " ...

Via New York Times: Boeing Dreamliner

Boeing modifies the Dreamliner production schedule again. ...

Via Boeing: New 787 Schedule: "This new schedule provides us the time needed to complete the remaining work necessary to put the 787's game-changing capability in the hands of our customers, said Boeing Chairman, President and Chief Executive Officer Jim McNerney. The design details and implementation plan are nearly complete, and the team is preparing airplanes for modification and testing. ... "




Boeing's breakthrough technologies in the Dreamliner are profiled in the video. ...



The company's systems are based on an open architecture. ...

Boeing 787 Dreamliner Systems: "An open architecture will be at the heart of the 787's systems, which will be more simplified than today's airplanes and offer increased functionality. For example, the team is looking at incorporating health-monitoring systems that will allow the airplane to self-monitor and report maintenance requirements to ground-based computer systems. "

Packaging and Putaway Process Automation

Layout For Lean Manufacturing Flows

Firan Technology Group will move to a new facility that will enhance its ability to sustain lean manufacturing performance. ...

... "FTG takes possession of the facility in July, 2007 and following a period for leasehold improvements, expect to move the business by October, 2007. The Company, with the assistance of expert consultants, is developing a facility layout optimized for Lean Manufacturing flows and has established a move plan to ensure no disruption of shipments to all customers. " ...

Via Firan Technology Group: Expanded Facility for FTG Aerospace

Lean Program Expansion Supports Increased Cash Flow at Sealy

Sealy reports good performance in its first quarter. An increase in costs was offset by continued improvements in manufacturing efficiencies, through its lean program. ...

... "This, combined with the start-up of our new domestic latex facility, the further integration of the new North American management team, and the expansion of our lean manufacturing program, should allow Sealy to continue to grow its market share and cash flow. " ...

Via Sealy Inc.: First Quarter Fiscal 2007 Results

Value Stream Map Workshop

Pelion offers one-day value stream mapping workshops ...

... "Initial one-day workshops will be led by Pelion's Chief Technology Officer Dave Gleditsch, a 30-year manufacturing industry veteran who has driven some of the world's most successful Lean transformation programs. The course is conducted in a teach & do format where students will learn in class how to create Value Stream Maps of both current and future states considering product flow strategies and customer value as the compelling drivers. Appropriate Lean Manufacturing principles will be used along the way as students work to define the current state, identify wastes and opportunities and discuss how Lean tools can be applied to create a Future State Map with an improvement plan. " ...

Via Pelion Systems: Value Stream Mapping: Beyond Whiteboards Workshop

Manufacturing Engineer Position: Understand Kaizen ...

Open position requires kaizen understanding ...

... "Requires a BS in Engineering and a minimum 5-9 years of experience in a manufacturing environment with heavy emphasis cost savings through improved processing. An understanding of Cellular Manufacturing, KanBan, Kaizen, Take time, Single Part Flow, Visual management, Poka-Yoke and 5's required. " ...

Via Spokesman Review: Link

Product-Focused Flows through Lean Six Sigma ...

Invistics creates solution offering that achieves the significant cycle time and inventory reduction in manufacturing using lean flow design, specialized software, and pull scheduling. ...

... "Built on modified Lean and Six Sigma principles, Invistics MachSix uniquely combines flow-based manufacturing methodologies, performance optimization software and variations on demand-based pull scheduling to help today's highly variable production environments gain greater advantage. In fact, Invistics' customers have been able to cut cycle times and inventory in half or more, while achieving on-time delivery rates as high as 99 percent. The MachSix solution alleviates bottlenecks by realigning plants into product-focused flows that leverage the best practices of Lean Manufacturing. Flow paths group products into families or value streams that visit similar pieces of equipment, allowing manufacturers to manage thousands of products with no dedicated machines." ...

Via Invistics: Invistics Has the Skinny on Lean Manufacturing: Why Some Enterprises Fail to Derive Benefits (PDF) ...

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

Manufacturing Software Support Lean Methods ...

Latest release of HighJump supply chain software supports lean manufacturing methods on the shop floor through touch-screen interface. ...

... "Manufacturing Execution: HighJump Manufacturing Advantage features a new, Web-based touch-screen user interface which has been optimized for the shop floor. This release also extends HighJump Manufacturing Advantage's material flow management to support lean manufacturing methods. By orchestrating the fluid movement of material through manufacturing processes, HighJump Manufacturing Advantage enables companies to meet tight production schedules without increasing inventory levels or adding labor. Material tracking and genealogy capabilities have also been enhanced to provide a greater level of inventory visibility and control of components and finished goods. " ...

Via HighJump Software: HighJump Software Extends Global Product Reach with Launch of HighJump Supply Chain Advantage Suite 9.0 ...

Space Launch Vehicle: Six Sigma Manufacturing Flow ...

Lean Six Sigma enables next generation of space launch vehicle ...

... "We are developing our manufacturing plans for the upperstage now. We are using lean-six sigma processes to develop the most efficient manufacturing flow possible for Ares I. " ...

Via NASA SpaceFlight: Pressing ahead with Ares I ...

Lean Manufacturing Stanley Furniture Efficiency Program ...

Stanley Furniture shows reasonable results for the quarter and highlights its lean manufacturing efficiency program, which has resulted in better working capital performance and higher cash flows from inventory reductions. ...

... "We are very pleased with strong cash flow for the first half of 2006 and the progress we have made in our continuous improvement efforts using lean manufacturing principles. These efforts have already resulted in a significant decrease in inventories while improving customer service levels and we believe we are laying the ground work to further improve processes and efficiencies. " ...

Lean Manufacturing Stanley Furniture Efficiency Program: Via Stanley Furniture: Stanley Furniture Announces Second Quarter 2006 Operating Results ...

Stanley is committed to lean manufacturing as a means of continuous improvement, as shown in its first quarter earnings announcement. ...

Comments on Stanley's lean manufacturing program from its first quarter management discussion: "Recently, we began reinvigorating our continuous improvement efforts using lean manufacturing principles, to improve processes and efficiencies. Near term, as these efforts allow us to continue reducing inventories, we anticipate lower production levels and operating margins. How quickly and to what extent we are able to lower costs, improve quality and reduce inventories is difficult to project, but we are confident this will position the Company to better compete primarily as a domestic manufacturer, execute our strategy and deliver value, concluded Scheffer. "

Stanley has created a competitive advantage through its on-shore manufacturing capability. This flexible blend of manufacturing capabilities is discussed in the 2005 annual report. ...

Stanley's Blended Manufacturing Strategy: Cellular Lean Manufacturing: "Central to executing this blended strategy are our four U.S. factories – domestic manufacturing capabilities we regard not only as our core competency but also a competitive advantage. Very simply, the ability to manufacture an extensive product line – accounting for some two-thirds of our revenues – in close proximity to our U.S. customer base is critical. We don't believe supply chains, which begin on the other side of the world can match our average shipping rate: less than 14 days.

To provide our products and support this broad distribution network, we have implemented a blended operating strategy combining efficient and flexible manufacturing processes with offshore sourcing of component parts and finished goods. We incorporate selected imported component parts and finished items in our product line to lower costs, provide design flexibility and offer a better value to our customers. We emphasize continuous improvement in our manufacturing and sourcing processes to enable us to continue providing competitive advantages to our customers, such as quick delivery, reduced inventory investment, high quality and value.

These manufacturing processes produce smaller, more frequent and cost-effective runs. We focus on identifying and eliminating manufacturing bottlenecks and waste, employing statistical process control and, in turn, adjusting manufacturing schedules on a daily basis, using cellular manufacturing in the production of components and improving our relationships with suppliers by establishing primary supplier relationships. In addition, a key element of our manufacturing processes is to involve all Company personnel, from hourly associates to management, in the improvement of the manufacturing processes by encouraging and responding to ideas to improve quality and to reduce manufacturing lead times. Furthermore, each of our manufacturing facilities is focused on compatible products to improve quality and lower production costs. "

Lean Manufacturing: Automated Processing Applications for Plasma Systems ...

March plans exhibition of it plasma processing applications for lean manufacturers. ...

... "March will be showcasing the versatile FlexTRAK plasma system. The FlexTRAK system is ideally suited for automated plasma processing in lean manufacturing environments while meeting the challenges of the advanced technology clinical applications. March supplies a complete line of award winning and patented systems for both automated and batch processing applications.

Plasma applications include ultra-cleaning, to enhance bonding and/or remove contaminants; surface barrier improvement and/or hardening, to reduce moisture penetration, chemical damage or wear; surface functionalization, to facilitate cell growth and desired surface activation; and surface wettability, to improve fluid flow and bonding. Typical clinical diagnostics products processed include microtitre or well plates, pipette or dispensing tips, filter media, pcbs and sensors. " ...

Lean Manufacturing: Automated Processing Applications for Plasma Systems: Via March Plasma Systems: March Plasma Systems to Exhibit at the Clinical Lab Expo Chicago, IL July 25 - 27, 2006 ...

Lean Manufacturing The Dell Front Office ...

Dell's lean manufacturing prowess finally shifts to the front office as it works to simplify its pricing model. ...

... "in dealing with Dell as a customer several years ago, I was dismayed that a company that is known for its lean manufacturing operations and direct-sales model had such Byzantine ordering and customer service processes. " ...

Lean Manufacturing The Dell Front Office: Via Motley Fool: Dell Switches Pistols ...

Dell pricing model announcement:

Via Dell: Dell To Simplify Pricing, Reduce Mail-In Rebate Offers: "Dell announced it will simplify its pricing structure and promotional offers, including reducing the number of mail-in rebates on products and services it sells to consumers and small businesses in the United States. The moves — part of the company’s efforts to make buying easier and improve the overall customer experience — will occur over 12 to 18 months, beginning in August with the reduction of mail-in rebates on InspironTM notebook computers and DellTM televisions. Dell will also reduce the frequency and complexity of promotions tied to the sale of DimensionTM desktop and Inspiron notebook computers, and other products such as televisions and services. Over time, the company projects a 70 percent reduction in the number of promotions per product line and about an 80 percent reduction in the number of promotions tied to a single product. "

Dell's implementation of lean allows it to be fast and adapt to changes in its marketplace, even though its supply chain model comes with some risks. Dell has shown success in dealing with the business cycles in its industry. ...

Via Fast Company: Living in Dell Time: "Fortunately, the same ethos of speed and flexibility that seems to put Dell at the mercy of disruptions also helps it deal with them. ... "

Via Quality Mag: Get Lean and Improve Quality: "Dell Computer Corp. uses lean manufacturing to build computers. For Dell, lean manufacturing has helped them weather an economic downturn ... "

Via Lean Blog: Once Again, Dell is Not TPS: "Their factories are great examples of flow, raw material comes in one side, finished product comes out the other, with minimal WIP in between. ... "

Lean Manufacturing Material Flow ...

UGS introduces new version of digital manufacturing software that supports more accurate digital representations of their plants, captures the layouts for future re-use, and optimizes the flow of material. ...

... "FactoryFLOW is the tool of choice for companies engaged in lean manufacturing, six-sigma, or other continuous improvement initiatives. With the release of FactoryFLOW Version 11.0, UGS is adding a variety of enhancements and new functionality to help manufacturers more quickly obtain detailed answers to their material flow questions, thus accelerating the optimization of material handling in their plants.

A new operator walk-path utility helps manufacturers design work cells to minimize operator walking time and distance. Enhancements allow the user to model multiple operators working simultaneously or in sequence in a work-cell or on a moving line where the part might be moving on a conveyor. Sophisticated reports and animations add even greater value to these analyses. " ...

Via UGS: UGS' Tecnomatix Improves Accuracy of Factory Designs and Optimizes Material Flow with New Versions of 3D Digital Plant Design Offerings: Latest Factorycad and Factoryflow Software Solutions Help Manufacturers Define State-of-the-Art Digital Factories for Competitive Advantage ...

Lean Manufacturing: Printer Manufacturer Achieves Success ...

Z Corporation achieves industry recognition for its lean manufacturing implementation. ...

... "Dubbed the Nobel Prize of Manufacturing by BusinessWeek, the Shingo Prize is recognized as one of the premier manufacturing awards and recognition programs in North America for the practice of lean manufacturing, a process that eliminates waste wherever possible. Z Corp. is one of four 2006 Northeast Shingo Prize recipients. Z Corp. employs lean manufacturing tools and techniques such as single-piece flow, customer-driven production, standardized work, kanban systems, and a quality at the source approach to drive improvement efforts. Since 2003, Z Corp.'s lean manufacturing processes have enabled the company to increase factory output by 300 percent, employee productivity by more than 45 percent, and inventory turns by more than 50 percent while maintaining an on-time delivery rate of more than 95 percent.

Z Corp. practices lean manufacturing on multiple levels – first, through our internal achievements and second, by enabling our customers to streamline their own manufacturing cycles, said Mike Vogel, director of operations, Z Corporation. Our lean manufacturing commitment is an integral part of our commitment to helping companies bring better products more quickly to market. Bruce Hamilton, president of GBMP and administrator of the Northeast Shingo Prize, called Z Corp. a model for continuous improvement and world-class results. We congratulate the employees of Z Corp. for making the company a strong, world-class manufacturer in Massachusetts and on a job well done. " ...

Lean Manufacturing: Printer Manufacturer Achieves Success: Via Z Corp: Z Corporation Recognized for Exemplary Lean Manufacturing Achievements ...

Lean: Dramatic Improvement in Cycle Time ...

Furnace supports dramatic cycle time improvements ...

... "The VF-20 is ideal for brazing parts of unusual shapes and repairing orphan parts from other heating processes. To facilitate continuous flow manufacturing, the VF-20 utilizes the latest advances in quick, clean solid state induction heating technology. The furnace requires less than eight minutes to reach 1900F; cool down time to 400F is less than 20 minutes. The furnace operates at high vacuum or partial pressure of an inert gas. The chamber has base vacuum of 5x10-6 Torr with a leak-up rate of less than 1 micron per hour. The VF-20 facilitates lean manufacturing by moving the vacuum heating process away from a centralized area, into the manufacturing cell, said IA President Steve Skewes. Our customers report improved manufacturing workflow with dramatic improvements in overall cycle time. " ...

Lean: Dramatic Improvement in Cycle Time: Via Induction Atmospheres: VF-20 Induction Vacuum Furnace ...

Kaizen Team: Lean Initiative for Laser Production ...

... "Mark Blodgett, President and Chief Executive Officer, announced that StockerYale's Montreal manufacturing facility has implemented a lean manufacturing initiative for its laser production lines. Lasers represent approximately 80% of the revenues generated in this facility. The Montreal site selected a cross functional team and worked with Bell Nordic, a Canadian consulting and training firm, on team leadership and self-directed work team training. The Company chose Bell Nordic to facilitate employee empowerment and mobilization for the Kaizen approach to lean manufacturing. After training, the Kaizen team implemented a revamped process flow for better customer response through shorter cycle times, improved product quality and for reduced waste costs from scrap, rework and warranty expense. Additional continuous improvement projects underway this quarter will complete a 5 S manufacturing environment and streamline strategic processes. " ...

Kaizen Team: Lean Initiative for Laser Production: Via StockerYale: StockerYale Announces Lean Manufacturing Initiative

StockerYale, Inc., headquartered in Salem , New Hampshire , is an independent designer and manufacturer of structured light lasers, LED modules, and specialty optical fibers for industry leading OEMs. In addition, the company manufactures fluorescent lighting products and phase masks. The Company serves a wide range of markets including the machine vision, industrial inspection, defense, telecommunication, sensors, and medical markets.

Lean Solution: Pull Scheduling Techniques ...

Infor delivers lean solution that leverages pull scheduling techniques ...

... "J&E/Earll has implemented Infor's Easy Lean solution, which has brought pull-oriented scheduling techniques to its production, which includes the manufacture and delivery of make-to order custom metal components and fabricated, finished and assembled final products for industries in some 30 states, Canada and Ireland.

Prior to incorporating Easy Lean into its Infor ERP VISUAL Enterprise software suite, J&E/Earll lacked the tools it needed to meet its delivery performance objectives. Without a formal scheduling or load/capacity capability, work did not flow efficiently. Production was consistently subject to expedited shipments and constantly shifting priorities. After Infor's Throughput Improvement PSO Group provided J&E/Earll with an approach to lean manufacturing, the company was able to use Easy Lean to reduce lead times dramatically, while making it considerably easier to maintain a 95-percent on-time performance level. " ...

Lean Solution: Pull Scheduling Techniques: Fast-Growing Manufacturer Solves Scheduling Challenges with Solution from Infor: Infor solutions enable J&E/Earll Manufacturing to slash lead times and gain 95-percent on-time delivery ...

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.

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 ...

Aggressive Six Sigma Combined with Price Increases ...

C&D must aggressively implement Six Sigma while increasing prices to maintain acceptable margins, in the face of dramatic raw material and energy spikes. ...

... "This rapid escalation in total lead costs has occurred simultaneously with copper and polymer resin price increases of over 8% over this same period and a similarly dramatic rise in the price of natural gas used in battery manufacturing operations. While we are continuing to focus aggressively on productivity improvements and cost reduction efforts as a part of our Six Sigma initiative, increases of this magnitude that occur in essential commodity costs must be addressed in part through increased pricing to our customers. We continue to work with our suppliers to drive economies in the supply chain and are hopeful that this difficult cost environment is of limited duration. " ...

Aggressive Six Sigma Combined with Price Increases: Via C&D Technologies, Inc.: C&D Technologies, Inc. Announces General Price Increase for Standby and Motive Power Products Effective March 1, 2006 ...

C&D Technologies, Inc. provides solutions and services for the switchgear and control (utility), motive (material handling), telecommunications, and uninterruptible power supply (UPS) as well as emerging markets such as solar power. C&D Technologies engineers, manufactures, sells and services fully integrated reserve power systems for regulating and monitoring power flow and providing backup power in the event of primary power loss until the primary source can be restored. C&D Technologies' unique ability to offer complete systems, designed and produced to high technical standards, sets it apart from its competition. C&D Technologies is headquartered in Blue Bell, PA.

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 ...

Manufacturing Performance Software: SAP Certified Integration ...

Invistics achieves SAP certified integration for its manufacturing performance software. ...

... "Invistics, developer of manufacturing performance optimization solutions for complex, asset-intensive industries such as consumer packaged goods and pharmaceuticals, announced that it has achieved SAP Certified Integration of its MachSix Integration Server. This product from Invistics provides interoperability between the mySAP ERP solution and Invistics MachSix advanced analytics, optimization and simulation software. Invistics software complements mySAP ERP by providing tools that allow manufacturers to account for demand variability, design and implement flow manufacturing processes that are more flexible, and conduct ongoing analysis of plant floor health based on real-time data while optimizing throughput, cycle time and customer service levels. Invistics uniquely combines MachSix software with a manufacturing performance methodology that leverages the proven principles of Lean Manufacturing and key components of Six Sigma. " ...

Manufacturing Performance Software: SAP Certified Integration: Via Invistics: SAP Certifies Integration of Invistics MachSix with mySAP ERP ...

Lean Technology: TPS Production Management ...

Factory Logic has digitized the Toyota Production System TPS to enable standardized production management. ...

Lean Technology: TPS Production Management: Via Factory Logic: FACTORY LOGIC SELECTED AS FINALIST FOR PRESTIGIOUS PACE AWARD: Company’s Enabling Lean Technology Recognized for Superior Innovation ...

... "Factory Logic, the leading provider of Lean solutions that meet the needs of the Customer Demand-Driven Factory, today announced that it has been selected as a finalist for a 2006 Automotive News Magazine’s PACE™ (Premier Automotive Suppliers’ Contributions to Excellence) Award. The coveted PACE Award honors superior innovation through technological advancement and business performance among automotive suppliers. Factory Logic’s Lean Operations Suite provides production scheduling and pull-based material flow applications designed to help manufacturers realize the tremendous potential of demand-driven lean manufacturing. " ...

Kaizen Events: 5S of Raw Material and Shipping Process

MEP supported the implementation of multiple Kaizen events on the raw material process and shipping area for Cedarworks. First pass yield was increased, cycle time was reduced, and space was increased through operational efficiencies gain through kaizen. ...

Kaizen Events: 5S of Raw Material and Shipping Process: Via NIST: Cedarworks: Assistance to Cedarworks ...

... "Cedarworks' 45 employees participated in Maine MEP's Timewise Lean 101 in order for all to understand the concepts behind Lean Manufacturing. A Value Stream Map of the manufacturing process from product receipt to wrapping for shipment was conducted, as well as a Value Stream Map of the Sales and Customer Service processes. Two Kaizen events were conducted as a result of the Value Stream Map process. One Kaizen event was a 5S of the raw material grading area and the other was a 5S of the shipping area. The Value Stream Map revealed a huge problem with the raw material being received and a problem with the flow of the material in the grading area. " ...

Lean Manufacturing Seminar Series: California ...

EMS will provide lean manufacturing seminars in California starting in early 2006. ...

Lean Manufacturing Seminar Series: California: Via EMS Consulting: EMS Consulting Group Announces a Series of Lean Manufacturing Seminars and Workshops in Southern California

... "EMS Consulting Group, Inc. has announced a public Lean Manufacturing certificate program beginning in February 2006 in Orange County, CA. The program will assist manufacturers with the challenge of implementing lean and maintaining continuous improvements. It includes a series of eight course modules designed to provide participants with targeted managerial and technical competencies in lean manufacturing. Participants will learn how to apply the key techniques of lean manufacturing: Value Stream Mapping, Lean Production Control and Inventory Management, One-Piece Flow, Cellular Manufacturing, Material Flow and Kanban, Five S, and Kaizen Events and tools. Lean Certification also includes the completion of lean manufacturing projects at attendee companies to reinforce the classroom learning.

The program will take place at the Doubletree Club Hotel Orange County Airport in Santa Ana, CA in eight Thursday sessions. The dates are February 2, 23; March 9, 23; April 6, 20; and May 4, 18. The sessions will run from 8:30 am to 4:30 pm. " ...

DesignFor Six Sigma: AS9102 Aerospace ...

DesignFor Six Sigma: AS9102 Aerospace: Via Cohesia: Aerojet Signs with Cohesia© for Global Specification Management: Requirements flow-down solution that enables 100% digitized characteristic accountability is expected to deliver return-on-investment within 12 months ...

... "The adoption of Design for Six Sigma and the implementation of industry standard process methodologies such as AS9102 for First Article Inspection in aerospace, hold the promise of reducing quality escapes from the product life-cycle. There are many factors that can lead to quality escapes including product requirements that are ambiguous, conflicting or incomplete. Detailed product requirements, which specify the engineering and manufacturing definition of a product, are driven primarily from information detailed in technical specifications. " ...

Six Sigma Error Proofing: Manufacturing Software

Manufacturing software enables Lean Six Sigma performance by accelerating component flow through the supply chain ...

Six Sigma Error Proofing: Manufacturing Software: Via IGear Online: Cosma International Selects I/Gear Manufacturing Software ...

... "In automotive manufacturing, I/Gear software enables a wide range of MES applications by providing a foundation for moving data between dissimilar systems and technologies, and the ability to push and pull data to and from the plant floor. I/Gear's application infrastructure software products enable more efficient deployment and maintenance of a near infinite amount of applications to include lot and part traceability, error-proofing and quarantine, on-demand label printing, dynamic scheduling, sequencing, build-to-broadcast, escalating notification, and manufacturing intelligence. The software suite is a complete package as it provides raw data collection and transport, as well as the graphical user interface to view and manage information. " ...

Louisville, KY based I/Gear, Inc., a leader in integrated manufacturing solutions, enables lean and six-sigma manufacturing by enabling manufacturers to make only what the customer orders, without defects, and compress the time required to pull components through supply chains and down through production lines – giving manufacturers a significant advantage over the competition. In addition to Magna, customers include UPS, Accuride Corporation, Dana Corporation, Cooper Tires, International Paper, and Alcan. I/Gear, Inc. is privately held.

Lean Manufacturing: Visual Map ...

The value stream map can be used to design a vision for the future manufacturing process and enable a collborative environment on the shop floor ...

Via TMAC: Value Stream Mapping ...

... "Visually describes the flow of material and information through a manufacturer's entire production systems. This allows for better understanding of the complete process. By graphically portraying the process, one is able to see exactly where value is added and value is lost. " ...

Lean Continuous Flow Operation Conversion

In a lean continuous flow operation, the manufacturing operations receive and produce only what is needed, exactly when it is needed. Continuous flow cells use pull systems to manage raw material and WIP, work in process ...

Lean Continuous Flow Operation Conversion: Via HB Maynard: York Casket Case Study ...

... "For York to remain competitive and meet Matthews operating objectives, division management needed to reduce unit costs by 20 to 40 percent. To reach this goal, York partnered with H.B. Maynard and Company, Inc. for assistance in converting the wood casket plant to a Lean Continuous Flow operation. " ...

Lean Manufacturing Visual-Marking Requirements

Lean Manufacturing Visual-Marking Requirements: Via Daily News: AliMed adds DuraStripe to its workplace safety line ...

Lean Manufacturing techniques can be as simple as marking visual lines on the factory floor to accelerate the flow of materials, using products such as Durastripe. Visual markings are a direct contributor to an corporate 5S program ...

... "DuraStripe, DuraShapes and DuraSigns are all marking products designed to promote on-the-job safety through visual communication. DuraStripe offers a solution to any company's safety or 5S programs and enables businesses to meet their lean manufacturing marking requirements. " ...

Additional references for applications of visual-marking in the manufacturing environment and the visual 5S factory:

Lean Building Blocks: MAMTC LEAN: Manufacturing consulting company helping small to ... The intent of a visual factory is that the whole workplace is set-up with signs, labels, etc.

5S Supplies: Where would you use this floor marking tape? "A place for everything, ... of visual controls needs to be part of a much larger lean manufacturing effort. ...

5S | Lean Thinking | Lean and the Environment | EPA: 5S provides the foundation on which other lean methods, such as TPM, ... The Visual Factory: Building Participation Through Shared Information (Portland, ...

Visual 5S Case Study: Factory simulation, to introduce the team to lean manufacturing tools and the ... 5S and Visual Management. The aim was to introduce the team to a method of ...

Lean Manufacturing Facility Design ...

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

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

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

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

Additional resources on lean manufacturing facility designs:

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

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

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

Tenneco Lean Six Sigma Operational Efficiency

Tenneco Lean Six Sigma Operational Efficiency: TENNECO AUTOMOTIVE REPORTS STRONG SECOND QUARTER OPERATING RESULTS ...

... "Our strategies for generating top-line growth and cash continue to be effective despite difficult and volatile market conditions," said Mark P. Frissora, chairman and CEO, Tenneco Automotive. We are also benefiting from our intense focus on managing costs and improving operational efficiency through Lean and Six Sigma. In addition, our balance in terms of products, markets, customers and vehicle platform mix gives us a competitive edge and continues to drive our progress." ...

Tenneco Automotive is a $4.2 billion manufacturing company with headquarters in Lake Forest, Illinois and approximately 18,400 employees worldwide. Tenneco Automotive 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 Automotive 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.

Production Operations Lean Manufacturing

Production Operations Lean Manufacturing: Del Monte Foods Company Reports Fiscal 2005 Fourth Quarter and Full Year Results; Announces Brand-Driven Strategic Plan, Including a $125 Million Share Repurchase Program ...

... "We improved our financial flexibility by generating strong cash flow in excess of $200 million. We also made structural changes to deal with the inflationary cost environment, including outsourcing transportation to a large logistics company to take advantage of their expertise and scale and introducing Lean Manufacturing in our production operations to improve manufacturing efficiencies. " ...

Del Monte Foods is one of the country's largest and most well-known producers, distributors and marketers of premium quality, branded and private label food and pet products for the U.S. retail market, generating over $3 billion in net sales in fiscal 2005. With a powerful portfolio of brands including Del Monte®, Contadina®, StarKist®, S&W®, Nature's Goodness™, College Inn®, 9Lives®, Kibbles 'n Bits®, Pup-Peroni®, Snausages®, and Nawsomes!®, Del Monte products are found in nine out of ten American households.

Lean Value Stream Mapping ...

Lean Value Stream Mapping: SEPO Upcoming Events

... "Lean (originally, Lean Manufacturing) is focused on eliminating waste and non value added activity throughout the value stream in order to reduce cycle time, cost, and variance. Value stream mapping is following a product or service from beginning to end and drawing a visual representation of every process in the material and information flow for the current state to understand how things currently operate (our baseline). Next, create a future state mapping of how value should flow (our vision). The assumption is that you can get better results from average people using brilliant processes than from brilliant people using broken processes. " ...

Lean Manufacturing DemandPull Management ...

Lean Manufacturing DemandPull Management: Webinar Demonstration ...

Web seminar by Pelion on their demand management solution for supporting lean manufacturing techniques, such as demand-pull ...

... "Manufacturing Process Optimization (MPO) Demand Manager, Date: Thursday, July 14, 2005 from 1:00-2:00 pm EST, Speaker: Dave Gleditsch, Chief Technology Officer, Pelion Systems, Inc. ... Objective: Dave Gleditsch, will host a complimentary Webinar to demonstrate Demand Manager and highlight how it’s driving automated demand-pull manufacturing at a major Tier 1 automotive supplier and a major consumer appliances manufacturer. " ...

... Demand-Pull system capabilities are integral to optimization of the manufacturing process which leads to excellence in lean manufacturing.

Pelion Systems is the market leader in Manufacturing Process Optimization (MPO) software products and services based on Lean, Six Sigma, and Flow Manufacturing principles. With Pelion, leading manufacturers are able to liberate capital, grow profits and sustain breakthrough performance by optimizing operations and extend their supply network to include suppliers, customers and outsourced service providers in their business transformation. Pelion MPO integrates easily with existing ERP, MRP and APS systems and is able to scale from a single facility to an enterprise implementation. Based in Boulder, Colo., Pelion has sales and marketing offices in Chicago, Detroit and Austin.

Lean Manufacturing Certification Program ...

EMS Consulting Group, Inc. Announces Lean Manufacturing Certification Program in San Diego

... "EMS Consulting Group, Inc. has just announced a public Lean Manufacturing certificate program for this fall in North San Diego County. The program will assist manufacturers with the challenge of implementing lean and maintaining continuous improvements. It includes a series of six course modules designed to provide participants with targeted managerial and technical competencies in lean manufacturing. Participants will learn how to apply the key techniques of lean manufacturing: Value Stream Mapping, Lean Production Control and Inventory Management, One-Piece Flow, Cellular Manufacturing, Material Flow and Kanban, Five S, and Kaizen Events and tools. Lean Certification also includes the completion of lean manufacturing projects at attendee companies to reinforce the classroom learning. The program will take place at the Grand Pacific Palisades Hotel in Carlsbad, CA in seven Wednesday sessions. The dates are September 7, 21; October 5, 19; November 2, 16, 30. The sessions will run from 8:30 am to 4:30 pm. These training sessions may also be taken separately. To register or obtain additional information, visit www.lean-manufacturing-training.com and view the public workshop schedule. " ...

Lean Six Sigma Job: Manufacturing Improvement Engineer ...

Manufacturing Improvement Engineer: UK job vacancies, online job search - jobs.telegraph.co.uk

... "You will have experience of hard systems such as six sigma, lean, Kaisan with a stronger leaning towards lean technology in cell manufacture through to continuous flow. " ...

Lean Initiatives: Operational Efficiency ...

Emerson Reports Second-Quarter 2005 Sales Up 10 Percent to $4.2 Billion; Earnings Per Share of $0.83

... "We continue to focus sharply on operational efficiency and lean manufacturing initiatives, with the average days-in-the-cash-cycle improving to 74 days in the quarter from 79 days in the prior-year period. We remain committed to the full-year targets of $2.1 billion of operating cash flow and $1.6 billion of free cash flow, which includes $0.5 billion of capital expenditures. " ...

Lean Manufacturing Techniques: Produce Positive Results ...

Plunge into Lean Manufacturing Helps Pelican Wire Increase Sales, Add Staff: Incorporating Lean Techniques Results in Six Figure Savings and Sales for Naples Company ...

... "To help identify areas to make changes and provide the necessary training to produce positive results, Pelican Wire called on the Florida Manufacturing Extension Partnership (Florida MEP) to help implement Lean Manufacturing techniques. Lean Manufacturing is an implementation technique that utilizes simple but effective methods to identify and reduce waste, and inventories, clear shop floors and streamline production processes all with a goal of decreasing costs and increasing productivity. Working with staff and management, David Ferguson and Jerry Nelligan, project managers for the Florida MEP, started with a Value Stream Map which literally mapped the flow of work through beginning to end of production line of a product for one of Pelican's main customers. " ...

The Florida MEP is an affiliate of the National Institute of Standards and Technology (NIST) under the U.S. Department of Commerce. The national MEP is a network of manufacturing extension centers that provide business and technical assistance to smaller manufacturers in all 50 states, the District of Columbia and Puerto Rico. Through MEP, manufacturers have access to more than 2000 manufacturing and business “coaches” whose job is to help firms make changes that lead to greater productivity, increased profits, and enhanced global competitiveness. For more information on the Florida MEP program call 321-939-4000.

Lean Enterprise Simulation Model ...

Simulation Model of the Lean Manufacture of NIF Assemblies

... "The concept of Lean Manufacturing, which was pioneered at Toyota, emphasizes continuous improvement through the identification of the value stream and the reduction of waste, and making value flow at the pull of the customer. The Lean concepts have been applied to many manufacturing applications in industry, most notably the major automotive plants. The NIF Lean Enterprise Team at Lawrence Livermore National Laboratory is working to apply the concepts of Lean Manufacturing to the production of the mechanical and optical assemblies which will comprise the NIF system. Application of the Lean concepts requires the identification of the value stream, along with streamlining of the production process, such that unnecessary steps are eliminated, and production flows according to the demand schedule in a 'just-in-time' manner." ...

Lean Manufacturing Effort Success Story ...

Parker Hannifin Announces Record Third Quarter Sales; Earnings From Continuing Operations of $1.18 Per Share ...

... "For the first nine months, cash flow from operations was $516.7 million, or 8.6 percent of sales. For the same period last year, cash flow from operations was $495.0 million, or 9.8 percent of sales. During the quarter, inventories were reduced by $48 million, which includes the effects of currency and acquisitions, and the company's ongoing lean manufacturing efforts. " ...

With annual sales approaching $8 billion, Parker Hannifin is the world's leading diversified manufacturer of motion and control technologies and systems, providing precision-engineered solutions for a wide variety of commercial, mobile, industrial and aerospace markets. The company employs more than 48,000 people in 46 countries around the world. Parker has increased its annual dividends paid to shareholders for 48 consecutive years, among the top five longest-running dividend-increase records in the S&P 500 index.

Lean MES Software Enables Manufacturing Optimization and Supply Chain Operation ...

Lean MES Software Enables Manufacturing Optimization and Supply Chain Operation: HighJump Software Empowers Customers to Bring Manufacturing ...

HighJump introduces new software product that synthesizes manufacturing optimization with supply chain management ...

From Business Wire (press release), CA ... This capability is in keeping with lean manufacturing and inventory management initiatives critical to the ongoing success of many businesses today. ...

... HighJump Software, a 3M company, the global leader in providing highly adaptable, best-of-breed supply chain execution (SCE) solutions, today announced that it has entered the manufacturing execution solution (MES) market with the release of its Manufacturing Advantage solution. This new offering differentiates HighJump from other SCE and MES solution vendors by helping customers combine optimization efforts for manufacturing and related supply chain operations in a single suite. This helps create a truly seamless flow of accurate, real-time demand and supply information throughout the supply chain from source to consumption. This product represents a natural extension of HighJump's roots in automated data collection, an area in which the company has continually developed its expertise for more than 21 years. Manufacturing Advantage can be implemented on either a stand-alone basis or alongside other HighJump solutions to increase levels of on-time and complete shipments, helping to ensure rapid return on investment. ...

HighJump Software, a 3M company, is the global leader in providing highly adaptable, best-of-breed supply chain execution solutions that streamline manufacturing and distribution from the point of source through consumption. HighJump's tightly integrated solutions empower operational excellence in the warehouse and optimize the flow of inventory throughout the supply chain by facilitating collaboration with customers, suppliers and trading partners. These comprehensive solutions combine robust, standard functionality; a best practices-based implementation methodology; and a uniquely adaptable architecture that facilitates fast, cost-effective system modifications. The result: the industry's lowest total cost of ownership for more than 700 satisfied customers worldwide. As an independent subsidiary in the 3M family of companies, HighJump leads the SCE software industry in financial strength and delivers on an unmatched commitment to innovation and quality. HighJump leverages these advantages to continually expand its solution footprint and empower operational excellence for domestic and multinational customers.

Lean Principles Improve Manufacturing Processes

MEP Helps Slocomb Industries Improve Manufacturing Processes

... "NIST's Manufacturing Extension Partnership (MEP) affiliate worked with Slocomb to develop and implement a three-phase plan to apply lean principles over a three year period. The first phase focused on the basics of production efficiency and involved redesigning the flow of information, improving workflow in each of Slocomb's five production lines, arranging visual cues, and cleaning and organizing the workspace. During the second phase, the MEP Center designed a system that allows the company to build to actual customer demand rather than to forecasts of demand, resulting in minimized raw material inventories and prevention of insufficient stock problems. The third phase of the plan focuses on additional training and will be completed in February 2003. " ...

Six Sigma Partnership Drives Culture Shift Transformation ...

Six Sigma Partnership Drives Culture Shift Transformation: Pelion Systems and the Lean Learning Center Partner to Help ...

Partners strive to transform the Lean Six Sigma culture within organizations ...

From PR Newswire (press release) ... Systems Pelion Systems is the market leader in Manufacturing Process Optimization (MPO) software products and services based on Lean, Six Sigma, and Flow ...

... Pelion Systems, the market leader in Manufacturing Process Optimization (MPO) solutions, and the Lean Learning Center (Novi, Mich.), a leading provider of Lean curriculum and consulting to a variety of industries, today announced a partnership aimed at helping manufacturers successfully adopt, implement and sustain Lean manufacturing processes. Pelion Systems and the Lean Learning Center will develop combined solutions that address the cultural side of Lean manufacturing transformation while accelerating the adoption process through the utilization of specialized software products. ...

The Lean Learning Center was founded in early 2001 by manufacturing and consulting industry veterans Andy Carlino, Jamie Flinchbaugh and Dennis Pawley to address the gaps and barriers that are holding back companies from successful Lean transformation. In combination with corporate partner Achievement Dynamics, a provider of management consulting, the companies
provide a full complement of lean transformation services. Industries served include manufacturing, healthcare, public utilities, retail, aerospace, communications, technology, investment equity, service and more.

Pelion Systems is the market leader in Manufacturing Process Optimization (MPO) software products and services based on Lean, Six Sigma, and Flow manufacturing principles. With Pelion, leading manufacturers are able to liberate capital, grow profits and sustain breakthrough performance by optimizing operations and extending their supply network to include suppliers, customers and outsourced service providers in their business transformation. Pelion MPO integrates easily with existing ERP and MRP systems and is available in desktop, site and enterprise editions. Based in Lafayette, Colo., Pelion has sales and marketing offices in Chicago, Detroit and Austin.

Lean Manufacturing Flow Path ...

Lean Manufacturing Flow Path: Invistics® Founder Joins National Science Foundation Committee

From PR Web (press release), WA ... operations scholars, the Flow Path Management System leverages years of expertise to overcome the obstacles of implementing lean manufacturing techniques in ...

... Invistics, developer of manufacturing performance management software, announced today that founder Tom Knight has been invited to join the Advisory Committee for the National Science Foundation (NSF) Small Business Innovation Research and Technology Transfer (SBIR/STTR) programs. Knight and other members of the panel represent the broad community served by the SBIR/STTR programs at NSF. Their insight and advice on small business programs help the SBIR/STTR programs meet federal legislation consistent with the NSF mission. The National Science Foundation is an independent federal agency created by Congress to promote the progress of science and is the major funding source for cutting-edge fundamental research in many fields including mathematics, physical science, computer science, engineering and the social sciences. ...

Invistics is the leading provider of manufacturing performance management software designed specifically for high-mix manufacturing environments. The Flow Path Management System® helps companies analyze and improve factory performance to achieve significant reductions in inventory while responding more quickly and reliably to customer demand. Utilizing Invistics solutions, customers have achieved over 99% on-time deliveries while reducing inventory by an average of 50% and cutting cycle times by more than half. Developed by experienced manufacturing veterans and leading operations scholars, the Flow Path Management System leverages years of expertise to overcome the obstacles of implementing lean manufacturing techniques in highly complex environments.

Lean Value Stream for NIF Assemblies

Simulation Model of the Lean Manufacture of NIF Assemblies

... "The concept of Lean Manufacturing, which was pioneered at Toyota, emphasizes continuous improvement through the identification of the value stream and the reduction of waste, and making value flow at the pull of the customer. The Lean concepts have been applied to many manufacturing applications in industry, most notably the major automotive plants. The NIF Lean Enterprise Team at Lawrence Livermore National Laboratory is working to apply the concepts of Lean Manufacturing to the production of the mechanical and optical assemblies which will comprise the NIF system. Application of the Lean concepts requires the identification of the value stream, along with streamlining of the production process, such that unnecessary steps are eliminated, and production flows according to the demand schedule in a 'just-in-time' manner." ...

Value Stream Process Map Plans The Lean Journey ...

Value Stream Mapping at MEP Source For Manufacturers ...

... "What is Value Stream Mapping? Value Stream Mapping is a tool used to create a material and information flow map of a product or processes. This powerful tool allows companies to map the flow of products in the back door as raw material, through all manufacturing process steps, and off the loading dock as finished product. This is the Value Stream. You begin the journey with the current state map - it shows you where you are. Then, you plan you lean journey with a future state map - it shows you where you're going and how you're going to get there. based on your Value Stream Map, you can streamline work processes, thereby cutting lead times and reducing operating costs. " ...

Axian Technology Lean Manufacturing ...

MEP Helps Axian Technology Achieve Lean Manufacturing ...

NIST MEP helps Axian Tech to embrace Lean principles ...

... "Axian Technology is a high volume manufacturer of high-tolerance, small-dimension aerospace and medical equipment. The company's strategy is to train all employees in the understanding and implementation of highly efficient manufacturing techniques with the goal of improving operations and reducing cycle times. Management realized that high inventory levels created order-to-cash flow lead times of up to a year or more. NIST Response: NIST's Manufacturing Extension Partnership (MEP) affiliate led a five-person cross-functional team through an exercise that identifies inefficiencies and process bottlenecks, and used the results to begin designing a new plant layout for Axian. The MEP Center performed an evaluation of Axian's products and designed a balanced machine and operator capacity/workload strategy. The team used an implementation checklist and action item list compiled by the MEP Center to integrate efficiency into operations." ...

Goodrich Lean Manufacturing Pays Off ...

SignOnSanDiego.com -- Goodrich division lands Airbus contract: Bruce V. Bigelow, San Diego Union-Tribune, writes... Recent contract wins by Goodrich have invigorated the viability of the Aerostructures Group and have validated the company's lean manufacturing transformation which is contributing to an increase in operational efficiency.

... Goodrich Aerostructures Group started in 1940 as Rohr Aircraft. Learn more about our proud history as a leading designer, producer and integrator of nacelle systems and other aerospace products. Since August 1996, the Aerostructures Group has been implementing Lean Manufacturing methods throughout all aspects of the business. Based on the Toyota Production System, Lean Enterprising solicits every employee's involvement in defining each product's value stream - the series of specific activities needed to get from raw material to finished item. The Group then uses week-long Lean events involving employees, customers, and suppliers to eliminate unnecessary steps from every value stream. The result? Through the use of Lean tools, the Aerostructures Group has realized 50% improvements in product build hours and flow times in many areas. The Group has also been able to support dramatic customer production rate increases and also absorb additional work with no increase in resources. ...

Heijunka Flow System ...

Heijunka: One Piece Flow System ...

... One-Piece Flow Manufacturing describes a reliable method for production flow that is well suited for the low volume production of a wide variety of products. UE’s One-Piece Flow Manufacturing system is a masterful blend of many reliable methods that applies the concepts of Lean Manufacturing, just-in-time, Takt time, levelized scheduling, finite loading, KanBan card system, Heijunka box, one-piece flow, and Kaizen methodology. ...

Best Practice Reference: UE’s One-Piece Flow Manufacturing system is a masterful blend of many reliable methods that applies the concepts of Lean Manufacturing, just-in-time (JIT), Takt time, levelized scheduling, finite loading, KanBan card system, Heijunka box, one-piece flow, and Kaizen methodology.

Heijunka Pull System ...

Heijunka Box Used at United Electric Controls - Watertown, MA:Shipping Using a Pull System

From Office of Naval Research's Best Manufacturing Practices (BMP) Program ...

... "UE uses a Heijunka box to schedule and control the flow of work: Since implementing its new shipping system, UE decreased the number of short shipments and incorrect part shipments, as well as eliminated many problems associated with the previous method. Orders are now consolidated for shipment which creates fewer transactions. Shipping supervisors can determine the status of the shipment by looking at the Heijunka box, and assign additional help as needed. Folders, outfitted on distribution carts, hold the paperwork and indicate the daily completion status of a customers order by which folder is used. In addition, UE reduced the number of domestic shippers from four to two, even though the volume of shipments has increased." ...

The Office of Naval Research's Best Manufacturing Practices (BMP) Program was created in 1985 to help businesses identify, research, and promote exceptional manufacturing practices, methods, and procedures. Its objective is to empower defense and commercial customers to operate at a higher level of efficiency and effectiveness. To this end, BMP has three core competencies represented by tools and resources that enable organizations to identify and apply best practices and become part of a vast, mutually supportive information exchange network.

Lean Manufacturing Initiative Drives Operational Efficiency of the Cash Cycle ...

Lean Manufacturing Initiative Drives Operational Efficiency of the Cash Cycle: Emerson Reports Record First-Quarter 2005 Sales Up 10 Percent to ...

From Business Wire (press release), CA ... We continue to excel on our operational efficiency and lean manufacturing initiatives, with the average days-in-the-cash-cycle improving to 74 days in the ...

... Emerson (NYSE: EMR) announced that net sales increased 10 percent to $4 billion in the first quarter of fiscal 2005, ended December 31, 2004, with increases in all business segments and double-digit sales growth in Process Management, Industrial Automation, and Network Power. Underlying sales were up 5 percent for the quarter, excluding the impact of exchange rates (3 percent) and acquisitions (2 percent). Net earnings for the first quarter increased 22 percent to $297 million, or $0.70 per share. Net earnings in the first quarter of fiscal 2004 were $244 million, or $0.58 per share. ...

Additional resources on improving the cash cycle with lean manufacturing ...

Ducati aims for new angle of lean with Oracle: cutting costs, reducing inventory investment and improving overall asset ... for the median; and cash-to-cash cycle time was ... œAt the heart of the lean movement is ...

Takt Times: Competitive advantage is possible by improving information flow. ... technology domain of computerized systems or lean approaches like kanbans. ... Cash-to-cash cycle. ...

Improve Cash Flow: Inventory Turns.... it impacts the "cash to cash" cycle - you've paid ... is a key element in improving inventory management ... a build to order system, lean manufacturing strategies and ...

Lean Manufacturing Performance Management Software is a Growth Area ...

Lean Manufacturing Performance Management Software: Invistics Secures $5 Million Series B Funding

From Business Wire (press release), CA ... Management System(R) is a manufacturing performance management solution that allows high-mix manufacturers to apply the latest lean manufacturing techniques to ...

... Invistics(R), developer of manufacturing performance management software, announced today that it has raised an additional $5 million in a second round of funding led by current investors H.I.G. Ventures, Intersouth Partners and Imlay Investments. ...

Invistics is the leading provider of manufacturing performance management software designed specifically for high-mix manufacturing environments. The Flow Path Management System(R) helps companies analyze and improve factory performance to achieve significant reductions in inventory while responding more quickly and reliably to customer demand. Utilizing Invistics solutions, customers have achieved over 99% on-time deliveries while reducing inventory by an average of 50% and cutting cycle times by more than half. Developed by experienced manufacturing veterans and leading operations scholars, the Flow Path Management System leverages years of expertise to overcome the obstacles of implementing lean manufacturing techniques in highly complex environments.

Additional resources on manufacturing performance management software ...

Manufacturing Performance Management... Manage Enterprise Performance Identify New: Better Match Supply & Demand Improve Inventory/Service Levels Drive Manufacturing Efficiencies Improve ...

Brooks Software and Business Objects Sign OEM Agreement: Brooks Software will use the complete Business Objects business ... with its own manufacturing data warehouse solutions for manufacturing performance management. ...

Pelion Systems to Host Webinar on Aberdeen´s New Manufacturing: these compelling insights into successful manufacturing performance management strategies," explains ... Pelion MPO is the industry's first software platform for ...

Lighthammer: customers by bringing Lighthammer‘s manufacturing performance management expertise into the ... Intelligence and Collaborative Manufacturing software products. ...

Six Sigma Driven Restructuring ...

Six Sigma Driven Restructuring: Tenneco Automotive Delivers Record Fourth Quarter and Full Year ...

From PR Newswire (press release) ... with price recovery from our customers, and by continuing to lower our costs and improve manufacturing efficiency through Lean and Six Sigma programs." Tenneco ...

... Tenneco Automotive (NYSE: TEN) reported a fourth quarter loss of $21 million, or 49-cents per diluted share, versus a net loss of $2 million, or 4-cents per diluted share, in fourth quarter 2003. Adjusted for the items below, fourth quarter net income increased to $8 million, or 17-cents per diluted share, compared with net income of $2 million, or 6-cents per diluted share a year ago. ...

Tenneco Automotive is a $4.2 billion manufacturing company with headquarters in Lake Forest, Illinois and approximately 18,800 employees worldwide. Tenneco Automotive 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 Automotive markets its products principally under the Monroe(R), Walker(R), Gillet(R) and Clevite(R)Elastomer brand names. Among its products are Sensa-Trac(R) and Monroe Reflex(R) shocks and struts, Rancho(R) shock absorbers, Walker(R) Quiet-Flow(R) mufflers, Dynomax(R) performance exhaust products, and Clevite(R)Elastomer noise, vibration and harshness control components.

Manufacturing Manager Job with Six Sigma Experience ...

Manufacturing Manager with Six Sigma Experience ...

From QCTimes.Com: Top Jobs ...

... "Manufacturing Manager: Tyco Valves & Controls Leading Manufacturer of industrial products seeks a Manufacturing Manager to oversee production operations of their Northwest Illinois manufacturing operation. The successful candidate will have a minimum of 5 years experince in overseeing and managing production in a manufacturing, machining, and assembly environment with a low to medium volume. This person should have prior experience with single-piece flow systmes, cellulerized work teams, kanbans and other continuous improvement programs. This person should have experience with mechanics, hydraulics, pneumatics, welding and CNC machining systems. This key leader should have a successful history of improving production efficiencies. Six Sigma Green or Black Belt preferred." ...

Lean Six Sigma Initiative Drives Gross Margin Improvement ...

IDEX Reports Record 2004 Orders, Sales, Net Income and Free Cash Flow ...

From impeller.net, IDEX Reports Record 2004 Orders, Sales, Net Income and Free Cash Flow ...

... "For the year, operating margins were 16.1 percent, 230 basis points higher than the 13.8 percent reported in the prior year. This improvement reflects volume leverage, along with a 120 basis point improvement in gross margin to 40.0 percent, resulting mainly from the company's Global Sourcing, Six Sigma and Lean Manufacturing initiatives. Higher total SG&A expenses year-over-year reflect acquisitions, volume-related expenses, and reinvestment in the businesses to drive organic growth. SG&A expenses as a percent of sales declined to 23.9 percent in 2004 versus 25.0 percent last year." ...

Packaging Industry Lean Six Sigma by the George Group: variety of services including global Lean Six Sigma and Lean deployments, focused ... Improve operational efficiencies to enhance gross margins and capitalize ...

Capturing Financial Benefits From Lean Manufacturing: methodologies of Lean Manufacturing, Six Sigma, and other ... revenue dollars, labor rates, gross margins, fixed versus ... on in the Lean Manufacturing engagement ...

IDEX Corporation: leveraging operational excellence tools like Lean Manufacturing, Kaizen, Six Sigma and Global ... The gross margin expansion allows reinvestment in R ...

Introduction to Six Sigma: File Format: PDF/Adobe Acrobat ... Lean thinking/manufacturing ... 2. Benefits of Six Sigma ... a gross profit margin of 20%, a simple analysis shows significant improvements to the gross profit margin ...

Webinar on Six Sigma Manufacturing Process Optimization MPO Services ...

Six Sigma Manufacturing Process Optimization MPO Services: Pelion Systems to Host Webinar on Aberdeen's New Manufacturing ...

From PR Newswire (press release) ... Systems Pelion Systems is the market leader in Manufacturing Process Optimization (MPO) software products and services based on Lean, Six Sigma, and Flow ...

... Pelion Systems, the market leader in Manufacturing Process Optimization (MPO) solutions, today announced it will host a Webinar presenting Aberdeen Group's latest research report: The Manufacturing Performance Management Strategies Benchmark Report. Chris Jones, Aberdeen's senior vice president of value chain research, and Richard Sherman, Pelion's senior vice president of marketing will co-present key findings from the study on Wed., Jan. 12, 2005 at 12:30 p.m. EST. ...

Pelion Systems is the market leader in Manufacturing Process Optimization (MPO) software products and services based on Lean, Six Sigma, and Flow manufacturing principles. With Pelion, leading manufacturers are able to liberate capital, grow profits and sustain breakthrough performance by optimizing operations and extending their supply network to include suppliers, customers and outsourced service providers in their business transformation. Pelion MPO integrates easily with existing ERP and MRP systems to optimize operations and implements without operational disruption. Based in Lafayette, Colo., Pelion has sales and marketing offices in Chicago, Detroit and Austin.

Additional resource on six sigma and manufacturing process optimization MPO ...

Manufacturing Process Optimization Studies Employing Taguchi: PROCESS OPTIMIZATION STUDIES. Lambda Research offers manufacturing process optimization studies employing Taguchi experimental designs. ...

Building Process Optimization with Supply Chain Management in the: File Format: PDF/Adobe Acrobat ... Production process optimization with whole house redesign that is supported by efficient supply chain management system will contribute to improve the overall ...

Manufacturing and Process Optimization: Research in manufacturing and process optimization is focused on two areas: Chemical process optimization (Bill Morton) The aim of this work is to develop ...

Kanban Techniques: JLG Industries, Inc. - McConnellsburg, PA - Continuous Flow Manufacturing ...

From Office of Naval Research's Best Manufacturing Practices (BMP) Program ...

... "focus was redirected to analyze up-stream operations. A steering team, organized to develop goals and objectives, established policies and procedures to ensure all personnel were working in the same direction. Company-wide teams were developed to plan and implement physical layout changes. All CFM problems were resolved when highlighted by teams. A facilitator was assigned the role of being the champion for CFM and its integration in the manufacturing process. Pilot areas were developed to prove out changes, and the changes were integrated throughout manufacturing. Pull and Kanban systems were implemented, supplier partnerships were developed, and rate-based scheduling was introduced." ...

Kanban Technqiues: Kaiser Electronics - San Jose, CA - Demand Flow Technology Manufacturing

From Office of Naval Research's Best Manufacturing Practices (BMP) Program ...

... "integrated assembly, test and inspection pull manufacturing system that has been widely used in the Far East and the United States. This method applies Kanban techniques to trigger the manufacturing process and incorporates components from almost all aspects of a manufacturing operation from line design to work instructions. The technique accommodates lot sizes down to one, and provides for flexibility in scheduling throughput by allowing operators to perform various processes within the manufacturing cells." ...

Kanban Techniques: Hamilton Standard Electronic Manufacturing Center (Hamilton Sundstrand) - Farmington, CT:Continuous Flow Manufacturing

From Office of Naval Research's Best Manufacturing Practices (BMP) Program ...

... "A Kanban system was implemented for WIP so that only the amount necessary to meet delivery schedules is allowed on the floor. With the Kanban system, problems are not masked by large quantities of WIP and the root cause of problems has to be addressed and corrected immediately. Operators are certified to inspect their own work with periodic audits by quality to ensure that quality standards are being maintained. Point-of-use storage is implemented on the floor with a Kanban system. Only the necessary assets to support the production schedule are allowed, and components are stored in cabinets on the production floor. First-in/first-out inventory rotation is maintained using a two bin system. The active bag has components pulled from it until it is depleted. The bar code label on the bag is then scanned and a new label printed in the finished stores, triggering the issue of another bag of material to the floor. The next implemented step is the Supplier Point-of-Use (SPOU) where the vendor delivers parts as needed directly to the manufacturing area." ...

Lean Manufacturing Career: TransAct Technologies Promotes Andrew Hoffman to Senior Vice ...

From PR Newswire (press release) ... material flow into manufacturing, managed operational transfer of production lines from Wallingford, CT to Ithaca, NY, implemented lean manufacturing in the ...

Experience in Lean Manufacturing can serve you well in your future career path ...

... TransAct Technologies Incorporated (Nasdaq: TACT), a leading producer of transaction-based printers for customers worldwide today announced the promotion of Andrew Hoffman to Senior Vice President of Operations. Mr. Hoffman will be responsible for all of TransAct's operations, including planning and production control, quality assurance, manufacturing, purchasing, manufacturing engineering, inventory control and logistics. ...

TransAct (Nasdaq: TACT) designs, develops, manufactures and markets transaction-based printers under the ITHACA(R) and MAGNETEC(R) names. In addition, the Company markets related consumables, spare parts and service. The Company's printers are used worldwide to provide receipts, tickets, coupons, register journals and other documents. TransAct focuses on two core markets: point-of-sale (POS) and banking, and gaming and lottery. TransAct sells its products to original equipment manufacturers, value-added resellers and selected distributors, as well as directly to end-users. The Company's product distribution spans across the Americas, Europe, the Middle East, Africa, the Caribbean Islands and the South Pacific.

RFID-enabled Lean Manufacturing: Factory Logic Announces RFID-based Material Flow Tracking & ...

From Business Wire (press release), CA ... Factory Logic, the leading provider of lean manufacturing and material management applications, today announced RFID Material Flow Tracking & Analytics -- an ...

... Factory Logic, the leading provider of lean manufacturing and material management applications, today announced RFID Material Flow Tracking & Analytics -- an innovative new component of its award-winning Factory Logic(TM) Lean Operations Management System. Designed specifically for factories using lean production techniques, this new capability helps factory personnel further reduce waste in terms of both inventory and manpower, while ensuring a smooth, reliable production flow. The new capability combines Radio Frequency Identification technology for shop floor tracking with powerful analysis of kanban movement to provide production and supply chain managers with insight into their actual material flow that has not been possible until now. Data collection is completely transparent and non-intrusive - it does not require any action on the part of shop floor personnel, nor does it interfere in any way with visual factory controls such as kanban, heijunka boards, etc. Used with Factory Logic's heijunka sequencing and scheduling, kanban management, and production monitoring applications, RFID Material Flow Tracking and Analytics provides factory personnel with automatic real-time tracking of kanban movement through the factory to collect precise measurements of actual production performance, including: demand, cycle time, batch sizes, inventory levels, and material velocity. ...

Factory Logic is dedicated to helping companies improve customer responsiveness and eliminate waste by delivering manufacturing and supply chain management solutions that support and enhance the use of key techniques pioneered in the Toyota Production System (TPS), and that make lean manufacturing practical for a wider range of manufacturing environments. With headquarters in Austin, Texas, Factory Logic is the first company to team lean manufacturing specialists with experienced software professionals to develop a standard software product built around the principles of lean production. The result is the Factory Logic(TM) Lean Operations Management System -- a new breed of factory and supply chain management solution that truly matches the operational needs of the lean enterprise while integrating smoothly with enterprise level business systems. In 2001, Factory Logic was the first software company to be awarded the Shingo Prize for its pioneering work.