Box-Swap Process Helps GM-Fort Wayne Keep on Truckin’ March 29, 2012
Posted by Jeff Fuchs in automotive, manufacturing.Tags: automotive, manufacturing
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The Fort Wayne, Indiana General Motors plant has developed an interesting approach to handle new large truck designs too big for its existing factory conveyance system. Trucks of different sizes that are ordered in the same color are paired together and their cabs and beds are switched for painting. Then they are returned to the proper vehicles. These and other innovative solutions to problems have made the plant highly successful.
To read more about this innovative solution to a vexing problem, click here.
Tumbling Down the Slippery Slope February 27, 2012
Posted by Jeff Fuchs in automotive, Lean Thinking.Tags: automotive, Lean Thinking
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Bill Waddell, writing at Evolving Excellence, writes about the demise of Toyota’s culture. Toyota, which has long prided itself on not firing employees to save money, has done just that in Australia. Despite the step back from a cornerstone of Toyota’s operating philosophy, Bill insists this has no bearing whatsoever on lean thinking itself.
Check out Bill’s Evolving Excellence post here.
How to Change a Culture: Lessons from NUMMI December 19, 2011
Posted by Jeff Fuchs in automotive, culture, Lean Thinking, Workplace Design.Tags: automotive, culture, Lean Thinking
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In an excellent article at Sloan Review, John Shook analyzes the joint-GM/Toyota factory endeavor (the New United Motor Manufacturing Inc.) which totally changed the workforce there. The Toyota Production System was employed, getting people to change how they behaved. Training, the way things are done, and organization all influenced a cultural change at the plant. The workforce there wanted to prove they could turn out quality products, so among the changes made was to use the stop-the-line andon process.
For a link to purchase the complete article, head here.
How to Change a Culture: Lessons from NUMMI December 19, 2011
Posted by Jeff Fuchs in automotive, culture, Lean Thinking, Workplace Design.Tags: automotive, culture, Lean Thinking
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In an excellent article at Sloan Review, John Shook analyzes the joint-GM/Toyota factory endeavor (the New United Motor Manufacturing Inc.) which totally changed the workforce there. The Toyota Production System was employed, getting people to change how they behaved. Training, the way things are done, and organization all influenced a cultural change at the plant. The workforce there wanted to prove they could turn out quality products, so among the changes made was to use the stop-the-line andon process.
For a link to purchase the complete article, head here.
GM’s Detroit-Hamtramck Plant Used Dark Days of Recession to Get Better December 18, 2011
Posted by Jeff Fuchs in automotive, lean, strategy.Tags: automotive, lean, strategy
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During the worst days of the recession, General Motors’s Detroit-Hamtramck Plant decided to focus on people, retooling the plant to turn out Chevy Volts and other electric cars. Through continuous improvement, standardized work, laying out the facility in a lean fashion, insourcing strategically, and adopting other lean strategies, the change was a success. In the process, waste has been reduced 15% and the company saves a million dollars annually simply by having switched certain riveting robots.
Check out the IndustryWeek article about the change here.
GM’s Detroit-Hamtramck Plant Used Dark Days of Recession to Get Better December 18, 2011
Posted by Jeff Fuchs in automotive, lean, strategy.Tags: automotive, lean, strategy
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During the worst days of the recession, General Motors’s Detroit-Hamtramck Plant decided to focus on people, retooling the plant to turn out Chevy Volts and other electric cars. Through continuous improvement, standardized work, laying out the facility in a lean fashion, insourcing strategically, and adopting other lean strategies, the change was a success. In the process, waste has been reduced 15% and the company saves a million dollars annually simply by having switched certain riveting robots.
Check out the IndustryWeek article about the change here.
Automakers Leading the Shift to a ‘Demand-Based Economy’ November 17, 2011
Posted by Jeff Fuchs in automotive, customer focus.Tags: automotive, customer focus
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Josh Cable, writing at IndustryWeek, describes how the automotive industry is switching from push to a pull model of production. Rather than mass-producing cars, consumer demands will begin to drive demand-based production. Instead of creating a set supply of cars, auto manufacturers are studying trends and demand through social networking sites, such as Twitter and Facebook, and how receptive people are to ad campaigns. This has allowed them to add “precision” to their method of product, price, place, and promotion.
Check out the IndustryWeek article here.
Automakers Leading the Shift to a ‘Demand-Based Economy’ November 17, 2011
Posted by Jeff Fuchs in automotive, customer focus.Tags: automotive, customer focus
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Josh Cable, writing at IndustryWeek, describes how the automotive industry is switching from push to a pull model of production. Rather than mass-producing cars, consumer demands will begin to drive demand-based production. Instead of creating a set supply of cars, auto manufacturers are studying trends and demand through social networking sites, such as Twitter and Facebook, and how receptive people are to ad campaigns. This has allowed them to add “precision” to their method of product, price, place, and promotion.
Check out the IndustryWeek article here.
Toyota Follows the Detroit Three November 17, 2011
Posted by Jeff Fuchs in automotive, Lean Thinking.Tags: automotive
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Over at Evolving Excellence, Kevin Meyer writes about how Toyota is succumbing to the practice of Ford, Chrysler, and General Motors: forcing suppliers to cut prices or face being replaced. That, says Mr. Meyer, is not the Toyota Way. The company grew so fast so rapidly that the expanded company is not as steeped in Toyota culture as it has been in the past.
Check out Mr. Meyer’s article here.
Toyota Follows the Detroit Three November 17, 2011
Posted by Jeff Fuchs in automotive, Lean Thinking.Tags: automotive
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Over at Evolving Excellence, Kevin Meyer writes about how Toyota is succumbing to the practice of Ford, Chrysler, and General Motors: forcing suppliers to cut prices or face being replaced. That, says Mr. Meyer, is not the Toyota Way. The company grew so fast so rapidly that the expanded company is not as steeped in Toyota culture as it has been in the past.
Check out Mr. Meyer’s article here.
The Happiest Man in Detroit April 20, 2011
Posted by Jeff Fuchs in automotive, lean, manufacturing.Tags: automotive, lean, manufacturing
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In an article at Bloomberg Businessweek, the ongoing efforts of Ford CEO Alan Mulally to transform Ford from a bankrupt company into the world’s most profitable automaker are examined. Not only has Ford continually beat the predictions of analysts, but its stock has soared to a 9-year high. Among the things Mulally did was to target new and emerging markets, as well as adjusting available products for existing markets.
Check out the Bloomberg Businessweek write up here.
The Happiest Man in Detroit April 20, 2011
Posted by Jeff Fuchs in automotive, lean, manufacturing.Tags: automotive, lean, manufacturing
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In an article at Bloomberg Businessweek, the ongoing efforts of Ford CEO Alan Mulally to transform Ford from a bankrupt company into the world’s most profitable automaker are examined. Not only has Ford continually beat the predictions of analysts, but its stock has soared to a 9-year high. Among the things Mulally did was to target new and emerging markets, as well as adjusting available products for existing markets.
Check out the Bloomberg Businessweek write up here.
Lean expert to head up VW manufacturing October 14, 2010
Posted by Jeff Fuchs in automotive, lean.Tags: automotive, lean
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Michael Macht, an expert in production, is stepping down as chief executive of Porsche AG to head up the Volkswagen Group’s global manufacturing network. Reuters news agency reports that Macht is “an expert in lean manufacturing” and says he “oversaw Porsche’s factories and ran a consulting firm that implemented similar just-in-time production methods at companies like Lufthansa.”
Read the Reuters news release here.
Lean expert to head up VW manufacturing October 14, 2010
Posted by Jeff Fuchs in automotive, lean.Tags: automotive, lean
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Michael Macht, an expert in production, is stepping down as chief executive of Porsche AG to head up the Volkswagen Group’s global manufacturing network. Reuters news agency reports that Macht is “an expert in lean manufacturing” and says he “oversaw Porsche’s factories and ran a consulting firm that implemented similar just-in-time production methods at companies like Lufthansa.”
Read the Reuters news release here.
Wi-Fi Sync Installation Boosts Ford’s Assembly Line Efficiency September 14, 2010
Posted by Jeff Fuchs in automotive, lean, manufacturing.Tags: automotive, lean, manufacturing
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Ford is now using WiFi to deliver Sync software to its vehicles equipped with MyFord Touch Technology. The automobile, which has a WiFi receiver for installation, is estimated cut 90 unique part numbers needed every time a Sync change occurs. The entire process to install the software via WiFi takes eight minutes.
Check out the SmartPlanet articles and photographs here.
Wi-Fi Sync Installation Boosts Ford’s Assembly Line Efficiency September 14, 2010
Posted by Jeff Fuchs in automotive, lean, manufacturing.Tags: automotive, lean, manufacturing
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Ford is now using WiFi to deliver Sync software to its vehicles equipped with MyFord Touch Technology. The automobile, which has a WiFi receiver for installation, is estimated cut 90 unique part numbers needed every time a Sync change occurs. The entire process to install the software via WiFi takes eight minutes.
Check out the SmartPlanet articles and photographs here.
An Up Close Look at a Toyota Assembly Line July 16, 2010
Posted by Jeff Fuchs in automotive, Lean Thinking, manufacturing.Tags: automotive, Lean Thinking, manufacturing
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Jon Miller, over at Gemba Panta Rei, highlights a new Toyota web initiative, which gives viewers the chance to see the Toyota assembly line. Called, “Your Toyota is My Toyota,” six videos on the Toyota Europe website give an inside look at the Burnaston, UK factory. Mr. Miller notes that you can catch glimpses of lean in action, such as pitch lines and a color-coded fixed position stop system.
Check out Mr. Miller’s review here.
An Up Close Look at a Toyota Assembly Line July 16, 2010
Posted by Jeff Fuchs in automotive, Lean Thinking, manufacturing.Tags: automotive, Lean Thinking, manufacturing
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Jon Miller, over at Gemba Panta Rei, highlights a new Toyota web initiative, which gives viewers the chance to see the Toyota assembly line. Called, “Your Toyota is My Toyota,” six videos on the Toyota Europe website give an inside look at the Burnaston, UK factory. Mr. Miller notes that you can catch glimpses of lean in action, such as pitch lines and a color-coded fixed position stop system.
Check out Mr. Miller’s review here.
UAW Launches Toyota Organizing Campaign July 16, 2010
Posted by Jeff Fuchs in automotive, economy, Lean Thinking, workforce.Tags: automotive, economy, Lean Thinking, workforce
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The new head of the United Auto Workers union, Bob King, has declared that the UAW will do whatever is necessary to bring foreign car manufacturers under union control. Mr. King explains how anti-union stances will be met with the understanding that things would be better if the company cooperated with the UAW. Mr. King has also expressed his desire to see UAW banners in front of every Toyota plant with the words, “Toyota Puts Profits Before People”.
Check out the Industry Week article here.
UAW Launches Toyota Organizing Campaign July 16, 2010
Posted by Jeff Fuchs in automotive, economy, Lean Thinking, workforce.Tags: automotive, economy, Lean Thinking, workforce
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The new head of the United Auto Workers union, Bob King, has declared that the UAW will do whatever is necessary to bring foreign car manufacturers under union control. Mr. King explains how anti-union stances will be met with the understanding that things would be better if the company cooperated with the UAW. Mr. King has also expressed his desire to see UAW banners in front of every Toyota plant with the words, “Toyota Puts Profits Before People”.
Check out the Industry Week article here.
GM On the Way to Zero Waste Goal June 18, 2010
Posted by Jeff Fuchs in automotive, green business.Tags: automotive, green, green business
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Jim Motavalli at the Wheels Blog at the New York Times highlights how 62% of General Motors’ plants (making up 43% of global production) no longer send any waste to landfills. The 2008 goal was to have zero waste at half of its plants by the end of 2010, and with only half the year over, 87% of the goal has already been met. Among the waste saving measures GM has entertained has been to incinerate paint sludge to generate heat.
Check out the blog post here.
GM On the Way to Zero Waste Goal June 18, 2010
Posted by Jeff Fuchs in automotive, green business.Tags: automotive, green, green business
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Jim Motavalli at the Wheels Blog at the New York Times highlights how 62% of General Motors’ plants (making up 43% of global production) no longer send any waste to landfills. The 2008 goal was to have zero waste at half of its plants by the end of 2010, and with only half the year over, 87% of the goal has already been met. Among the waste saving measures GM has entertained has been to incinerate paint sludge to generate heat.
Check out the blog post here.
Chrysler CEO Optimistic About Future June 18, 2010
Posted by Jeff Fuchs in automotive, manufacturing.Tags: automotive, manufacturing
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Chrysler, having posted a first-quarter operating profit of $143 million, wants to have a public stock offering as quickly as possible. Chief Executive Sergio Marchionne had hoped the company would break even or would make $200 million for the year. The first quarter is set to shoot through that ceiling. Plans are also underway to unveil new, smaller and more fuel-efficient vehicle models for 2011, adding to a robust new vehicle lineup.
Check out the New York Times article here.
Chrysler CEO Optimistic About Future June 18, 2010
Posted by Jeff Fuchs in automotive, manufacturing.Tags: automotive, manufacturing
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Chrysler, having posted a first-quarter operating profit of $143 million, wants to have a public stock offering as quickly as possible. Chief Executive Sergio Marchionne had hoped the company would break even or would make $200 million for the year. The first quarter is set to shoot through that ceiling. Plans are also underway to unveil new, smaller and more fuel-efficient vehicle models for 2011, adding to a robust new vehicle lineup.
Check out the New York Times article here.
Toyota “At Its Most Interesting When It Has Problems” March 23, 2010
Posted by Jeff Fuchs in automotive, Lean Thinking.Tags: automotive, Lean Thinking
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Michael Ballé has examined the Toyota recall and has drawn two possible conclusions about the automanufacturer’s issues: Either Toyota is halting sales to fix an increasingly rare problem; or, according to the press, Toyota has finally bowed to the will of the United States government to fix a long-running problem. Mr. Ballé gives Toyota the benefit of the doubt, and explains that Toyota must find the problem, examine causes, propose and implement solutions, and then evaluate the results. Toyota does not think in the box, however. One of its lean successes comes in that it doesn’t solve problems for people: it solves it with them in a collaborative process, using their input.
Check out Mr. Ballé’s analysis here.
