A socks manufacturing company in India turned to TQM to improve its supply chain. In Part One, the case study describes the process of elminating a significant cost for the company – delivery delays. This week, Part Two of the case study looks at the broadening of the application of process improvement beyond deliveries. The…
A socks manufacturing company in India turned to TQM to improve its supply chain. In Part One, the case study elminates a significant cost for the company – delivery delays. Part Two of the case study looks at the broadening of the application of process improvement beyond deliveries. A fledgling socks manufacturing company in India was working to…
The following are selected highlights of a corporate leadership profile of FLEXcon. The complete article – with more details about Lean application and how the company avoided layoffs during the recession – is available for purchase on the iSixSigma Marketplace. FLEXcon positions itself for growth by embracing Lean at every level More than 50 years…
Boeing has announced plans to overhaul its CH-47 Chinook helicopter production facility in Ridley Park, Pa., USA, and incorporate Lean renovations that will allow the plant to increase production by 50 percent.
The U.S. Army has recently awarded Choctaw Defense, owned by the Choctaw Nation of Oklahoma, a three-year, $20 million performance standard contract to design and manufacture the Camel II potable water trailer system, which provides water for troops in virtually any location.
A recent report by the Scottish Manufacturing Advisory Service (SMAS), a business advisory group sponsored by the government of Scotland, found that continuous improvement efforts, including Six Sigma, have resulted in more than £21 million worth of productivity benefits across the region over a 12-month period in 2010-11.
Bulked continuous filament (BCF) carpet yarn manufacturing is a commodity product for which production from a single plant can be measured in the hundreds of millions of pounds annually. Hundreds of draw-texturing positions produce 15-pound bobbins of textured yarns continuously – as many as 3,000 in a month from a single position – which are…
A manufacturing plant that makes Merillat kitchen cabinets in Mt. Jackson, Va., USA, has received the 2011 Virginia Governor’s Environmental Excellence Silver Award in recognition for its years of environmental stewardship, including the savings achieved via a recent Six Sigma project.
Lehman Trikes, a manufacturer of three-wheeled motorcycles, has promoted its quality and safety manager, Terree Matson-McCoy, to the position of vice president of operations.
Polymer chip manufacturing is a multi-step, large-volume process that makes hundreds of millions of pounds of products annually at a typical plant. Unlike fiber extrusion, which requires the use of multiple units of specialized equipment, chip manufacturing involves fewer machines operated in either continuous or batch modes. Chip manufacturing is often driven by operator decisions,…
Sixteen manufacturing firms located in the West Midlands region of the United Kingdom are poised to receive Six Sigma business management training as part of a European Union initiative to spur competitiveness in the region.
Finch Paper, based in Glen Falls, N.Y., USA, has named Black Belt Ken Chartier as its new director, quality and continuous improvement.
With orders soaring for its workhorse 737 passenger jet, Boeing Commercial Airplanes has announced that it is expanding its Lean production facility in Renton, Wash., and increase its workforce at the plant by 1,200 workers by 2013.
After making a $3 million investment and securing funding from the Economic Development Coalition for Asheville-Buncombe County, N.C., roofing firm W.P. Hickman Co. is poised to open its newly expanded Lean facility near Asheville, N.C., USA, on May 26.
Lion Vallen Industries, a maker of protective equipment for military and emergency-services personnel, was named the Progressive Manufacturer of the Year for the small and mid-sized company category at the Manufacturing Leadership Summit in Palm Beach, Fla., USA.
Following the keel-laying ceremony of the 14th and final ship in the T-AKE dry cargo-ammunition shipbuilding program in San Diego, contractor General Dynamics NASSCO said that Six Sigma-based improvements deployed over the last decade have reduced the labor costs of the $6 billion program by 60 percent.
Aviation parts supplier LMI Kitting LLC, has been named the Georgia Small Manufacturer of the Year at the Governor’s Awards, held in Atlanta.
Nexteer Automotive, a manufacturer of steering and driveline systems, has reported significant operational savings at its plant near Saginaw, Mich., USA, by using motion analysis software commonly used by figure skaters.
According to a March 24 report from Objective Analysis, nearly 25 percent of the world’s semiconductor production capacity is in Japan, as well as more than 60 percent of the silicon wafers from which semiconductor chips are created. In 2010, industry analysis firm iSuppli determined that Japan held about 35 percent of the $31.5 billion…
Regal Beloit Corp., a manufacturer of electric motors and motion controls, has promoted Master Black Belt Jonathan J. Schlemmer to the title of chief operating officer.
In a recent study of 100 senior manufacturing staff, British magazine Works Management (WM) found that the largest barrier to the adoption of continuous improvement (CI) programs is lack of cooperation from their staff.
Honda is only the latest of several automobile manufacturers to report production slowdowns in the wake of last month’s Japan earthquake, tsunami and nuclear crisis – triple catastrophes that have crippled global car production supply chains and reduced overall capacity by as much as 30 per cent, according to the British newspaper The Independent.
Senior Hargreaves, a British ventilation ductwork manufacturer, has adopted Lean methodologies to help the company add 28,000 square feet of new space to its existing facility in Bury, Lancashire.?
WABCO, a supplier of components for the commercial vehicle industry, has opened a new production facility in Jinan, China, showcasing the company’s Lean Six Sigma program.
Stealth Components, a distributor of electronics equipment, has added Andrée Kiser to its team as director of operations and quality control.
Sleep Innovations, a designer and manufacturer of foam bedding products, has hired Robert West as Chief Operating Officer to implement Lean practices across the enterprise.
Ford Motor Co. said is it nearing completion of the demolition phase of a $600 million project to revamp its Louisville Assembly Plant in Louisville, Ky., USA, which will include the addition of several Lean processes.
Doncasters Group Ltd., a U.K.-based global manufacturer of precision-engineered machine parts, has met its internal goal of training three members of its staff as Lean Six Sigma Black Belts in three different locations.
The typical plant control room has changed dramatically over the years. Alarm management – which once was simply a sound or flashing light designed to get the control room operator’s attention – has changed dramatically, too. Many control rooms have replaced analog panel boards with multiple screens of bright and colorful representations of plant equipment….
The Association for Manufacturing Excellence (AME) has released a call for nominations for its annual Manufacturing Excellence Awards, recognizing North American manufacturing sites that have demonstrated the highest quality in their operations.
Lauren Manufacturing, a supplier of extruded and molded sealing products, has announced the promotion of Halle A. Norris from plant manager to vice president of manufacturing.
The publishing industry is on the threshold of major structural changes. The arrival of e-books is only the first threat, and it is having an impact sooner than expected. For example, Amazon.com sold more e-books than paper books in the first quarter of 2010. The credit crunch also has reinforced retailers’ demands for smaller, more…
After a contentious 10-year competition with European rival EADS, the Boeing Co. won a hard-fought $35 billion contract to supply the U.S. Air Force with new refueling tanker aircraft, due in part to the Lean methods the aerospace manufacturer recently adopted for its 767 line.
Cummins operates three plants San Luis Potosi, Mexico, which produce and ship products daily to distribution centers in the United States. These plants produce systems such as reconditioned engines, alternators, and filtration and exhaust systems. Two of the three plants were looking for ways to reduce the high costs of trucking the products, so Rebecca…
Vestas, the Danish wind-turbine manufacturer, has hired David Gels as its new vice president of quality and process excellence. The company also hired two other executives to its North American operations: Ramon Mendoza as warranty management chief specialist and David Sword as government relations director for Canada.
Delta Faucet Co. has promoted its continuous improvement (CI) manager Todd Shadburn to the position of senior CI engineer.
With assistance from Spanish wind-turbine manufacturer Gamesa, nonprofit foundation Tekniker and several other European technology firms, COSMOS seeks increases in turbine quality, as well as lower costs and faster manufacturing times, according to a release from Ibermática. According to the COSMOS consortium, many European turbine assembly operations involve both manual labor and work done by…
Soon after announcing its $3.5 billion takeover of St. Louis-based box maker Smurfit-Stone Container Corp., paperboard company Rock-Tenn said it plans to expand its Lean Six Sigma program to the new acquisition.
RS Precision, a manufacturer of a wide rnge of machine-tooled parts, has hired Allan Brill, a certified Lean expert and Six Sigma Black Belt, to the newly created position of continuous improvement manager.
Based in Bardon, Leicestershire, U.K., Benson Group is one of the country’s largest carton suppliers, producing packaging for both the food and pharmaceutical industries at its 130,000-square-foot facility. The Bardon plant produces sheets of printed cardboard that is then cut and glued for use in the food industry as containers. With the adoption of Lean…
Circuit board maker EE Technologies (EET) is planning to add a fifth production line at its Emplame, Sonora, Mexico, facility and adopt Lean techniques to help meet rising demand for its products.
Onity, a provider of electronic locking systems, has announced that it has appointed W. Laird Hamberlin to the position of president. Laird, who is a certifed Six Sigma Black Belt, will be based in Onity’s global headquarters in Duluth, Ga., USA.
LaBarge Inc., a St. Louis-based manufacturer of electronic componenets, has named Black Belt Charles Metheny as the new operational excellence site leader for the company’s Berryville, Ark., USA, operation.
Running a call center is like handling a job interview: First impressions are critical. Good intentions do not make up for tardiness, ill-fitting clothing, dirty shoes, the inability to reasonably pronounce the interviewer’s name or ignorance about what the company does. The primary purpose of a call center is to increase the profitability of the…
Consumer electronics firm H.C. Starck Inc. will receive the “Evolution of Manufacturing” Award, an honor bestowed upon manufacturing companies located in Northern Ohio, USA, that have adapted their business plan to better compete in a global economy.
Health Enhancement Products Inc., a manufacturer of health and wellness products in Scottsdale, Ariz., USA, has hired Troy Davis to fill the newly created position of operations manager.
Crane Merchandising Systems, one of the world’s largest suppliers of vending machines and vending payment systems, has employed Lean techniques to consolidate two of its manufacturing operations into a single facility in Williston, S.C., USA.
IC-TAG Solutions, a manufacturer of radio-frequency identification (RFID) tags, has begun the first phase of its Lean program, which includes a program to reuse and recycle materials and save energy during the manufacturing process.
Utlility vehicle and crane manufacturer Dueco Inc. has appointed Michael Johnson as its new materials manager. With more than 17 years of experience in the materials and operations field, Johnson has had extensive training in the Lean and Six Sigma methodologies.
In December 2010, the company announced that it would be ramping up production of its popular 777-series wide-body jet from 5 airplanes a month to 7 per month in 2011, and again to an average of 8.3 a month in 2013. Earlier in the year, Boeing also said it would be boosting production of its…