Lean Manufacturing 2007 Audio Recordings and Proceedings

An Inside Look at Reliability and the Toyota Production System
David Absher, Manager of Facilities Control, Maintenance, Operations and Engineering Department, and Johnathan Ritter, Assistant Manager, Skilled Trades, Toyota Motor Manufacturing Kentucky

Toyota is the standard for American manufacturing plants, especially those on the journey to become lean. With its recent roll-out of MR-50 (Maintenance Reduction 50 Percent), Toyota is also the standard for maintenance and reliability organizations within those plants. In this keynote session, we offer a rare opportunity – a panel discussion with Toyota maintenance and reliability experts. These leaders share their views and insights on lean, Toyota, MR-50, the development of global facilities control plant management requirements and the development of technical skill advancement strategies for the next generation of Toyota technicians. 67 minutes

Overcoming the Challenges of Lean in Facilities Maintenance
Mark LaRue, Plant Services Division Manager, Honda Mfg. of Alabama

In today's competitive manufacturing environment, maintenance professionals are tasked with improving the manpower efficiency of the maintenance operation, while rising to the task of limiting downtime and providing effective maintenance programs. How can you solve this problem without increasing the overall direct labor cost or overcontracting with large numbers of specialized suppliers? Honda Manufacturing of Alabama has chosen to outsource all of the facilities maintenance function. The organization chart is more of a flat line, where barriers are removed, allowing for a smoother workflow and a higher quality of work while still achieving cost targets. This presentation explains why HMA chose to outsource its facilities maintenance and how it has managed the outsource relationship over the last six years. 51 minutes

Designing Effective Maintenance in a JIT Factory
Wayne Vaughn, Director of Maintenance, Harley-Davidson

In this keynote session, you’ll learn about overcoming the challenges of creating a proactive maintenance approach in just-in-time factories that run 24 hours a day. Wayne shows how the maintenance strategy must be in alignment with the corporate goals, objectives and strategy, and how these strategies must then be designed for smooth execution on the shop floor. He also shows how this process must evolve from learning what works and what does not and how to ensure that operations and maintenance are always working together. Finally, Wayne discusses briefly where he believes maintenance is going over the next several years and how Harley-Davidson is preparing itself for the future. 60 minutes

Training, Problem-solving and Standardized Work
Bryan Lund, Lean Coordinator, Global Lean Office, Energizer

The current challenge for Energizer's lean leaders such as Lund is to lead the implementation of TWI (Training Within Industry) within the company's global facilities. In 2004, Bryan was a member of a local network of colleagues interested in improving approaches to standardized work. After two years of research and trials, this network of colleagues and local businesses is adopting TWI and rethinking current approaches to problem-solving and standardization of work.

Bryan provides case studies on how Training Within Industry and lean principles are used to increase uptime, improve reliability and improve maintenance in Energizer's operations. 54 minutes

Integrating the Reliability Business Case with Six Sigma and Lean Methodologies
Paul Casto, Reliability Technology Manager, Eastman Chemical

Today's business environment continues to drive manufacturers to lower cost to positively affect the bottom-line value created in their businesses. And yet, one area of value creation that has traditionally been ignored is the plant maintenance and reliability function. Maintenance is often seen as a "necessary evil", not as an area which adds value on the income statement. Also, within many companies, Six Sigma and lean methods have become the preferred tools for improving bottom-line performance. Six Sigma is a disciplined, data-driven process that incorporates the know-how, experience and synergy of knowledgeable teams to develop and implement innovative solution. Lean is a tool used to continuously drive waste out of the manufacturing process. Company management teams know and understand these improvement methods. As a result, the common-sense application of these methodologies to maintenance and reliability problems can result in increased management support for reliability and dramatic improvements in cost and availability. This discussion reviews the reliability business case and provide practical methods to create value in maintenance and reliability. 63 minutes

Implementing Build-to-Order
Michael Giuliano, Operations Manager, and Barb Molnar, Lean Project Manager, Nordson Corporation

With direct operations in 30 countries worldwide, Westlake, Ohio-based Nordson Corporation is the world's leading manufacturer of systems that apply adhesives, sealants and coatings during manufacturing operations. Nordson Finishing includes the Container Coating, Powder Coating and Liquid Finishing businesses.

For several decades, Nordson Finishing has been successfully executing a build-to-stock business model. This segment has more than 2,000 saleable products and is a high-mix, high-variability, mid-low-volume factory model. In 2007, a build-to-order initiative was created and is currently being brought to life in Amherst, Ohio, with great success. In this presentation, Giuliano and Molnar discuss the build-to-order model at a conceptual level, followed by the actual plans, transition, implementation and real results of this powerful initiative. 52 minutes

TPM's Role in a Lean Enterprise
Steve Eberhardt, Organizational Effectiveness Leader, AstenJohnson

AstenJohnson, a South Carolina-based manufacturer of paper machine fabrics, filaments and equipment, has made incredible strides through the implementation of reliability and lean manufacturing concepts. Of particular importance has been the company's use of Total Productive Maintenance as a foundational element of lean. In this presentation, Eberhardt provides a road map and progress report on these initiatives, as well as points out elements that can hinder your plant's lean reliability success. 47 minutes

Paying Attention to the Foundation
Mike Cicholski, Life Cycle Engineering (and formerly with U.S. Steel Alcoa)

With numerous corporate and location assignments, Mike became manager of Change Management Services facilitating change with more than 500 cross functional and intact work groups across Alcoa and eventually became Director of ABS and Organizational Effectiveness working with one of Alcoa’s largest business units responsible for the socio-technical transformation of numerous manufacturing locations. For the last ten years, Mike has been focused on implementation of the Toyota Production System while educating and coaching leaders, crew members, supervisors, union members and team leaders to be effective implementers of the system. 55 minutes

Using Kaizen to Increase Your Equipment Effectiveness
Mike Wroblewski, President and certified Six Sigma Black Belt, Victory Alliance Technologies

Learn how to unlock the power of kaizen to increase your equipment effectiveness and create better flow. This presentation outlines the lessons learned on the lean journey, reviews practical problem-solving tools and explores the different kaizen approaches to reduce the six major machine losses.

Mike's energetic and highly entertaining presentation outlines a host of maintenance and reliability improvement opportunities based on his wealth of experiences, including nearly two decades leading lean efforts at the Hill-Rom business unit of Hillenbrand Industries. While at Hill-Rom, he was taught the principles of lean and the Toyota way, under the sensei approach, directly from the original lean masters such as Shigeo Shingo. 51 minutes

Lean Maintenance Tools for Zero-Breakdown Productivity
Dr. Jay Lee, University of Cincinnati/NSF CIMS Program

This presentation discusses how to achieve zero-breakdown status on equipment reliability and productivity. Emerging technologies and tools are presented to transform the current “fail and fix” practices to “predict and prevent” methodology. In addition, case studies are used to illustrate the lessons learned from industrial applications. This is truly the future of maintenance and the future of lean. 58 minutes