Design of Experiments: DOE Taguchi Method ...

Taguchi method ensures good performance in the design stage using design of experiments ...

... "Genichi Taguchi, a Japanese engineer, proposed several approaches to experimental designs that are sometimes called Taguchi Methods. These methods utilize two-, three-, and mixed-level fractional factorial designs. Large screening designs seem to be particularly favored by Taguchi adherents. " ...

Design of Experiments: DOE Taguchi Method: Via NIST: 5.5.6. What are Taguchi designs?

Lean Manufacturing: Chrysler Doing It Right ...

Lean manufacturing implementation at Chrysler Group positions it for success as its sister division must make hard choices. ...

... "New DaimlerChrysler AG CEO Dieter Zetsche defended job cuts at the company's Mercedes division, saying in an interview made available Saturday that the division could learn something about lean manufacturing from Chrysler Group. " ...

Lean Manufacturing: Chrysler Doing It Right: Via The Charlotte Observer: Zetsche defends cuts, says Mercedes could learn from Chrysler

Additional resources on Chrysler lean manufacturing progress:

Lean Manufacturing, Kaizan, Kanban, Just In Time Articles: "Chrysler Group is moving up the rankings quickly, helped by a 9.5% improvement in engine productivity. Since 2001, the company has gained 19% in productivity across assembly, stamping and powertrain measures."

The Daimler-Chrysler Collision - Another merger in search of that elusive synergy By James Surowiecki: "And there is the hope that Chrysler's lean manufacturing style will help Daimler shake up a company that is still heavy with layers of middle management. Chrysler makes four times as many cars as Daimler with fewer than half the workers ... "

The Tale of a New Manufacturing Economy: "This adverse downturn was significant in another way. After years of denial, it drove many manufacturers, such as the US automotive industry, to become more productive by embracing the Toyota Production System (aka, lean manufacturing). After implementing lean, Chrysler raised its total productivity by over 7% last year ... "

MES Manufacturing Execution Systems: Factory Visibility ...

Manufacturing execution system (MES) investments are growing as firms are seeing the benefits of increased visibility on the factory floor. Ken Schnepf explores the trends in manufacturing. ...

... "The trouble is that most companies don't have the systems in place to capture the information they need. This is where MES comes in. Manufacturing operations have recently become the second highest investors in MES, according to Roach. " ...

MES Manufacturing Execution Systems: Factory Visibility: Via Plant Services: Putting technology to work

Boeing Lean: Supply Chain Integration ...

David Greising explores the success and challenges for Boeing as it embraces lean manufacturing principles which require tight integration in the supply chain. ...

... "Boeing executives are doing what the experts recommend: giving suppliers real-time access to its information systems so they can know when and where Boeing needs deliveries." ...

Via Chicago Tribune | BOEING'S BIG TEST: SUCCESS

Boeing Lean Manufacturing Production System ...

Boeing will build the 787 on a new production system based on lean manufacturing principles. ...

... "The company also has adopted a new lean-manufacturing production system based on Toyota's. The new assembly line in Everett for the 787 will be the ultimate application of lean principles, with suppliers sending in huge completed sections from around the globe for a three-day assembly process. " ...

Via KING5 Seattle News: Successor to Boeing 737 likely to be built in state ...

Additional resources on Boeing lean manufacturing principles:

Via Boeing: Environmental Reports - Creating - Build it Lean: "These ideas are called Lean Manufacturing, which draws on the insights and skills of the men and women whose hands form our products. It starts at the detail level, where small increments of waste can go unnoticed in the great push to assemble an airplane. By stepping out of their regular routine and taking stock of their work space and processes, with the coaching of a manufacturing expert, our employees have mounted a grass-roots revolt against waste."

Via Boeing: Lean Enterprise Successes: "To date, IDS application of Lean principles has led to products with fewer parts, are easier to build and support, have higher quality and are more affordable. The net result is higher customer satisfaction, better opportunity for growth and increased shareholder value."

Via Boeing: All Systems Go - Vol. 2, No. 3: "The introduction of Lean manufacturing to the shop floor in 1999 changed everything. Today the Mesa site is one of the company's Lean showpieces and is a candidate for the prestigious Shingo Prize."

Manufacturing Yield Management: Software Ranks High ...

Syntricity software ranks high for semicon manufacturing yield management according to study. ...

... "Syntricity's enterprise yield management system allows global companies to quickly and accurately analyze yield information, which enables faster time to market and enhanced supply chain visibility. FSA's study found that Syntricity's software is used by 51 percent of those using commercial yield management systems. Syntricity is also used by the broadest range of companies, with revenues ranging from $6 million to $1 billion. The next closest supplier reflected a share of 14 percent. Syntricity's satisfaction rating was the highest of all yield management system vendors, with a ranking four on a five point scale. FSA's report was compiled from the responses of 28 fabless semiconductor companies, highlighting the MIS systems used by these companies. " ...

Manufacturing Yield Management: Software Ranks High: Via Syntricity: SYNTRICITY YIELD MANAGEMENT SOFTWARE LEADS IN FSA MANAGEMENT INFORMATION SYSTEM SURVEY: Rates high in customer satisfaction and adoption by fabless semiconductor companies ...

Manufacturing Excellence: Plant Integration

Phil Aponte and Greg Richards explore the levels of manufacturing excellence that could be aciheved through higher levels of business process integration. ...

... "Consistent systems that reach from the production or process level (controls) to the MES/ERP system remain rare. It's not a lack of IT-supported processes that prevents consistency because all the most important IT software components are available in principle. The real issue is using them effectively." ...

Manufacturing Excellence: Plant Integration: Via ISA | Integration Fuels Plant SMARTS

Total Quality TQM Reputation ...

Company launches new forklift built on foundation of total quality. ...

... "All of these innovations, available now on the Fortens H2.0-3.5FT series, are designed to contribute to the lowest cost of operation, maximum uptime, operator preferred ergonomics and unmatched performance. Put together they produce a truck that continues Hyster's reputation for progressive thinking, total quality, and leaves the competition standing. " ...

Total Quality TQM Reputation: Via MHW Magazine: Hyster Fortens saves on downtime by selecting the right gear ...

TQM Total Quality Management Process

... "The process of TQM (total quality management) started in Rane group on 1999 with the first workshop by a Japanese expert Dr Washio. A complete reappraisal of business process was undertaken to plug the gaps in command and control systems, provide adequate training to workers and involve them in participatory management, said L Ganesh, vice-chairman, Rane group at the felicitation meet. " ...

Via News Today: Rane group felicitated for winning Deming ...

Six Sigma Test Process: Lower Failure Rate ...

Six Sigma process is used in test process to lower failure rate at disk drive maker. Chris Mellor explores disk drive companies and the successes and failures in the marketplace. ...

... "There have been design improvements, an extended test process to reduce infant mortality and improve the product (so as) to lower the failure rate. Some Raptor mechanisms are re-used. The extended test process is all part of a Six Sigma process, a manufacturing quality discipline which Seagate also uses. " ...

Six Sigma Test Process: Lower Failure Rate: Via ARNnet | All is not quiet on the Western Digital front

Additional resources on using Six Sigma in the test process:

Via Westgard QC Lesson: From Method Validation to Six Sigma - Translating Method Performance Claims into Sigma Metrics: "While it is probably disconcerting to find that a single test process has two different Sigma metrics, it's not surprising that a test performs differently at different levels. It would be far more unusual if a test performed the same at all the levels of concentration. For the high level control, a Sigma metric of 4.56 is actually acceptable. But for the low level control, a Sigma metric of less than zero is clearly bad. "

Via Conference Presentation Summary: "Running these tests by hand became cumbersome so the group developed a nightly test harness that runs each of the quality tests and collects all of the data to present a single comprehensive view of measured quality. It was a small move from this point to start a continuous test process that runs a slimmed down set of the quality tests whenever code is checked into the source code repository. The continuous measure of quality then is the final blending of extreme programming with Six Sigma. "

Software Verification and Validation Consulting - Best Practices - Via Wipro Technologies: "This model supports the improvement of test processes, offers insight into maturity of test processes, defines new test strategy and recommends immediate improvement steps. "

Six Sigma: Disaster Recovery Planning

Firm, recognized for its Six Sigma capability, suffers from inability to rapidly recover from business upset, affecting customers data. ...

... "Northgate recently won a Six Sigma award for Excellence; surely not for its disaster recovery and business continuity planning. " ...

Six Sigma: Disaster Recovery Planning: Via Techworld.com - Data retention needs

Manufacturing Software Extends Channel Partners ...

Incuity extends its reach through new channel partners. ...

... "Incuity EMI connects to a variety of off-the-shelf plant floor historian products – such as Wonderware’s IndustrialSQL Server historian, the GE iHistorian, OSIsoft’s PI database, Rockwell Automation’s RS Bizwire Historian and any other OPC HDAcompatible historian – to access archived production data and allow users to manipulate, view, trend and report on it in the appropriate context. More importantly, it connects to multiple types of data sources across all levels of medium and large companies, from plant floor systems to enterprise business applications. It offers sophisticated capabilities for manipulating, viewing and sharing data throughout larger organizations. Incuity can access information over any network, using standard browsers, and process it as requested so users can analyze it from within the application software they already use to do their jobs – whether it’s automation control systems, word processors, spreadsheets, graphics, data mining or other programs. " ...

Manufacturing Software Extends Channel Partners: Via Incuity: Incuity Software Names Spartan Controls, BridgeWare As Value-Added Resellers for Western Canada & Korea ...

Incuity Software, based in Mission Viejo, California, is a pioneer in the creation of data management systems for reporting, analysis and business intelligence applications in manufacturing and process companies. More than 45,000 seats of the company’s products have been installed since 1998, in 13 languages and in more than 40 countries. In addition to its headquarters operations in California, Incuity has a regional sales office in Nevada and maintains an advanced solutions development group in Burlington, Ontario, Canada.

Manufacturing Intelligence Software Evolution ...

Report explores the evolution of manufacturing intelligence software and the benefits of plant to business integration: visibility. ...

... "The ability to unlock the operational data that would empower plant managers and executives to make informed, timely decisions has eluded many companies until relatively recently. However, a new generation of MES (manufacturing execution systems) and manufacturing intelligence systems is enabling the collection, presentation, and analysis of critical, real-time data to decision makers throughout the enterprise and the supply chain. " ...

Manufacturing Intelligence Software Evolution: Via Aberdeen Group: Manufacturing Transparency: Turning Visibility into Value ...

Software Supports Manufacturing Agility ...

Newest release of manufacturing execution software (MES) supports agile and adaptable manufacturing models where market requirements are in a constant state of change. ...

... "FlexNet is a highly pliable execution software that can be deployed stand-alone or to extend the value of an organization's ERP, CRM, PLM or other business systems. The software is both a broad strategic operations execution platform that ties together the diverse activities of a manufacturer's operations, as well as a modular suite of applications that can be deployed as needed to provide a tightly coordinated manufacturing solution. Built for Adaptability, Agility: FlexNet 9.3 has been built for adaptive manufacturing, an emerging strategy driven by operations execution systems that provide the flexibility, visibility and integration required to support constantly changing business requirements. The results are optimal efficiency, quality and responsiveness, which can translate into higher profitability and customer satisfaction. " ...

Software Supports Manufacturing Agility: Via Apriso Corporation: APRISO CORPORATION ANNOUNCES FLEXNET VERSION 9.3: Newest Version of Widely Used Software Provides Greater Manufacturing Agility, Adaptability ...

Additional resources on manufacturing agility:

Via Control Engineering - Role of Controls in Product Lifecycle Management: "Moreover, as an enabler for working collaboratively in the early stages of product development, digital manufacturing enables design and automation engineers to work together to quickly develop designs that can be manufactured most readily and economically within the available production facilities. Such integrated systems also support greater manufacturing agility, giving companies greater flexibility in changing operations according to shifting demands of competition and customer preference."

OUTLOOK 2005: Integration & Data Master: Via Managing Automation: "The goal for every commercial offering is to simplify the integration effort, lower cost and enable business and manufacturing agility. And everywhere you turn a vendor has an integrated solution sell for you. "

Via NEMI: GenRad Product Commercializes Technologies from NEMI’s Plug And Play Factory Project: "The adoption of NEMI's FIS standards could greatly reduce the amount of time it takes to integrate new equipment and software systems into the manufacturing supply chain. This capability is critical for maintaining manufacturing agility as well as for increasing the efficiency of shop floor operations, stated John Cartwright, co-chair of the NEMI FIS TIG and manager of Factory Information Systems at Intel."

Kaizen: Lean Staffing Techniques

In a competitive market, kaizen and lean staffing techniques can be a competitive edge. Marla Dickerson explores the techniques of cola maker Ajegroup who know how to compete in the marketplace. ...

... "Lean staffing is another cost-cutting tool. Spokesman Paredes said the company's modern equipment, coupled with so-called kaizen, or continuous improvement, techniques, have helped it reduce the number of workers on each of the Huejotzingo plant's seven production lines to eight, which he says is fewer than half that of a typical bottling facility. " ...

Kaizen: Lean Staffing Techniques: In Mexico, Taking Fizz Out of the Cola Giants - Via Los Angeles Times

Additional resources on lean staffing techniques:

Kaizen Rapid Process | Lean Thinking | Lean and the Environment | Via EPA: "Kaizen, or rapid improvement processes, often is considered to be the building block of all lean production methods. Kaizen focuses on eliminating waste, improving productivity, and achieving sustained continual improvement in targeted activities and processes of an organization. Lean production is founded on the idea of kaizen or continual improvement. This philosophy implies that small, incremental changes routinely applied and sustained over a long period result in significant improvements. "

Feature Article - Building Better Powertrains Through Lean Approaches at Toyota: "The addition of three machinists known as the 'kaizen team' swells the ranks to a grand total of 17. And this kind of lean staffing exists throughout TMMWV. Toyota can operate in this mode because of a single-minded pursuit of the lean practices of the Toyota Production System (TPS). "

Via OnDemandJournal: "There is no greater roadblock to continuous improvement than a person who is fighting to keep a job that's not needed, especially if he's in a management role. Since small businesses already have lean staffing, that's less likely to be a problem. "

Lean Manufacturing Rebuilding After Disaster

Clark Door is recognized for its rebuilding efforts through an award for manufacturing. ...

... "The award recognised the impressive way that the company incorporated best practice lean manufacturing techniques in rebuilding its business from scratch. " ...

Lean Manufacturing Rebuilding After Disaster: Via Business Gazette: BOUNCING BACK IN STYLE AFTER FLOODS ...

Lean Manufacturing Food Processing Seminar ...

Seminar in lean manufacturing for food processing is upcoming. ...

... "Representatives of Idaho food processing companies can learn the principles of lean manufacturing during a full-day workshop in January. Lean Manufacturing for Food Processors takes place 8 a.m. to 4:30 p.m., Jan. 11 at the Red Lion Hotel Canyon Springs in Twin Falls and Jan. 24 at the Owyhee Plaza Hotel in Boise. " ...

Lean Manufacturing Food Processing Seminar: Food processor workshops slated

Cost Control: Lean Manufacturing Contributes ...

Anusha Shrivastava interviews Frank J. Johnson, head of Manufacturing Alliance of Connecticut, to understand the challenges facing Connecticut businesses and how lean manufacturing contributes to productivity and cost control. ...

... "So not being able to control these costs is very frustrating for them. On top of everything else, their customers are trying to push their costs down. Things have been better in 2005 than 2004 because of lean manufacturing, but I can tell you that they are bogged down by high costs. " ...

Via The Waterbury Connecticut Republican American: Building a case for manufacturing ...

Lean Manufacturing Versatility: Workforce Flexibility ...

Hillary Wundrow reports on the specialized shrink-wrap used to protect engines enroute to their destinations. The company, Fairbanks Morse, leverages lean manufacturing techniques and is creating a versatile workforce. ...

... "The project fits in perfectly with the company's lean manufacturing initiatives, improving the versatility of Fairbanks Morse's work force. Currently the company is working on three major engine projects. One of its projects is an effort to disassemble, clean and inspect four U.S. Navy ship engines damaged from Hurricane Katrina. " ...

Lean Manufacturing Versatility: Workforce Flexibility: Via Beloit Daily News: Shrink wrap protects mammoth engines ...

Lean Technical Excellence Center ...

Local leader returns to post in the UA system, where technical excellence center focuses on lean manufacturing. ...

... "ATN is made up of 14 regional centers of technical excellence that link the UA System, Auburn and EDPA with two-year colleges across the state. Each specializes in a high need area, such as business consulting, human resources and organizational development, lean manufacturing and engineering technical services. " ...

Lean Technical Excellence Center: Via Daily Home - Former Pell City mayor returns to area with college post ...

MBA Course Includes SixSigma ...

... "Elective topics covered during the 30-hour program will include the voice of the customer, process improvement including Six Sigma, sustainable development, leadership, negotiations and maximizing shareholder value. " ...

Via CMU: CMU LAUNCHES PROFESSIONAL MBA ...

Six Sigma Reliability Measures Success ...

Rich Weissman explores successful leadership methods, that leverage six sigma to drive reliability. ...

... "Mainstream quality related concepts such as statistical process control (SPC) and six sigma all work to identify and reduce waste and variation in a process, resulting in improved reliability and associated cost containment and management. Reliable products are cost effective, reducing service and warranty expense and improving customer satisfaction. Reliability is good business. " ...

The Manufacturer.com - Relying on leadership ...

Transactional Six Sigma: Non-Manufacturing Processes ...

Article explores the implementation of Six Sigma in transactional business processes. ...

... "Six Sigma in non-manufacturing: Six Sigma began with quality improvement in manufacturing processes. However, its application has since been suitably adapted and successfully deployed not only in the non-manufacturing functions such as design, commercial, accounting, etc, but even in service-oriented industries such as IT, banks, schools, etc. " ...

Via domain-B: Quality : Service with a Sigma-ile ...

ISO9001 Manufacturing Plant Certification ...

Firm receives ISO9001 certification. ...

... "It has implemented manufacturing and business excellence programs involving Six Sigma, Kaizen and benchmarking with the world's best practices." ...

Via albawaba: Ducab receives prestigious ISO 9001 certification for its newly opened Abu Dhabi plant ...

Execution Key to Innovation

Book review explores the importance of execution in converting ideas into reality. ...

... "Govindarajan and Trimble remind readers that strategic innovation isn't the same as continuous process improvement (such as that of GE through Six Sigma), process revolution (as in Wal-Mart with the help of RFID tags), and product/service innovation (like what consumer product manufacturers and toy companies often do). " ...

Via The Hindu Business Line : Capacity for innovation is the product of creativity and execution ...