Continuous-flow manufacturing--what went right, what went wrong: 101 mini-case studies that reveal lean's successes and failures

571 Pages·2019·13.698 MB·English

by  Schonberger, Richard

Contents Contents
Flow Manufacturing –
What Went Right, What
Went Wrong
101 Mini-Case Studies that Reveal
Lean’s Successes and Failures

Flow Manufacturing –
What Went Right, What
Went Wrong
101 Mini-Case Studies that Reveal
Lean’s Successes and Failures
By
Richard J. Schonberger
A PRODUCTIVITY PRESS BOOK
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Library of Congress Cataloging-in-Publication Data
Names: Schonberger, Richard, author.
Title: Continuous-flow manufacturing--what went right, what went wrong : 101
mini-case studies that reveal lean’s successes and failures / Richard J.
Schonberger.
Description: Boca Raton : Taylor & Francis, Routledge, 2019. | Includes
bibliographical references and index.
Identifiers: LCCN 2018032754 (print) | LCCN 2018036990 (ebook) | ISBN
9780429432170 (e-Book) | ISBN 9781138362291 (hardback : alk. paper)
Subjects: LCSH: Just-in-time systems--Case studies. | Lean
manufacturing--Case studies. | Production control--Evaluation.
Classification: LCC TS157.4 (ebook) | LCC TS157.4 .S39 2019 (print) | DDC
658.5--dc23
LC record available at https://lccn.loc.gov/2018032754
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
Contents
Preface ....................................................................................................xi
PaRT I advanced Process Improvement Found in the
1980s: 32 Tour Reports (27 U.S.; 5 Other Countries)
Chapter I-1 Apple Computer, Inc., Fremont, CA, 1988 ....................1
Chapter I-2 Coach Leatherware, New York City, 1987 .....................5
Chapter I-3 KONE Subsidiary, Robbins & Myers, Dayton, OH,
1983–85 ..........................................................................10
Chapter I-4 Analog Devices, Inc. (ADI), Wilmington, MA, 1987 ......13
Chapter I-5 Westinghouse, Asheville, NC, 1986 .............................19
Chapter I-6 WCM at Associated Equipment Co., St. Louis,
MO, 1988 ........................................................................22
Chapter I-7 Ahlstrom Pump, Mantta, Finland, 1989. .....................24
Chapter I-8 Day-Brite Lighting Division of Emerson Electric,
Tupelo, MS, 1986 ...........................................................29
Chapter I-9 Appleton Electric Division of Emerson Electric,
North Chicago, IL, 1986 ...............................................34
Chapter I-10 Gleason Tool/Harbor Metal Stamping, Rochester,
NY, 1987 .........................................................................37
Chapter I-11 Hoover Universal, Tillsonburg, ON, Canada, 1986 ......41
Chapter I-12 3M Data Products Division, Hutchinson, MN, 1984 .......46
Chapter I-13 3M Graphic Preparation Systems, Weatherford,
OK, and St. Paul, MN, 1986 ..........................................49
Chapter I-14 Campbell Soup, Paris, TX, 1985 ...................................60
Chapter I-15 Mars, Veghel, Netherlands, 1989. .................................67
v
vi • Contents
Chapter I-16 Caterpillar Manufacturing Programs, Peoria,
IL, 1987 ........................................................................72
Chapter I-17 J. I. Case/Tenneco, East Moline, IL, 1989 ..................76
Chapter I-18 Manufacturing at Formica, Evandale, OH, 1988 ......82
Chapter I-19 Sealed Air Corp. (SAC), Fair Lawn, NJ, 1989 ............85
Chapter I-20 Sealed Air Corp., Hodgkins, IL, 1989. .......................90
Chapter I-21 Russell Athletic, Alexander City, AL, 1988 ...............93
Chapter I-22 BIC Corp., Milford, CT, 1989 .....................................96
Chapter I-23 Zanussi, Florence, Italy, 1989 ................................... 101
Chapter I-24 Interchecks, Inc., Centralia, WA, 1989 ....................104
Chapter I-25 Zytec Corp., Redwood Falls, MN, 1987 ....................111
Chapter I-26 Honeywell, Plymouth, MN, 1989 ............................. 116
Chapter I-27 Charles Machine Works, Perry, OK, 1989 ...............120
Chapter I-28 AT&T Little Rock, Little Rock, AR, 1988 ................123
Chapter I-29 Haworth Corp., Holland, MI, 1983 and 1984. .........127
Chapter I-30 Steelcase, Inc., Grand Rapids, MI, 1988 ..................132
Chapter I-31 Steelcase, Inc., Grand Rapids, MI, Jan., 1989 ..........139
Chapter I-32 Hon Company, Muscatine, IA, 1987 ........................148
PaRT II Maturing Process Improvements in the 1990s:
36 Tour Reports (30 U.S.; 5 Other Countries; and One for a
Company with Plants on Both Sides of the U.S. Border)
Chapter II-33 Hon Company, Muscatine, IA, 1990 ........................155
Chapter II-34 Steelcase, Inc., Grand Rapids, MI, 1990 ..................162
Chapter II-35 Baldor Electric Co., Fort Smith, AR, 1990 ..............168
Chapter II-36 Miller Brewing Co., Trenton, OH, 1993 .........................173
Chapter II-37 Amtico Co. Ltd., U.K., Division of
Courtaulds, 1991 .......................................................179
Contents • vii
Chapter II-38 Eli Lilly, Indianapolis, IN, 1996 .............................183
Chapter II-39 Johnson Controls, Electromechanical Systems
Unit (EMSU), Milwaukee, WI, 1990 ......................190
Chapter II-40 Johnson Controls Interiors, Holland, MI, 1999 .......197
Chapter II-41 Siecor Corp., Hickory, NC, 1990 ............................203
Chapter II-42 Four Seasons Remanufacturing Division,
Standard Auto Parts, Coppell, TX, 1994 ...............208
Chapter II-43 East Bay Generator, North Oakland, CA, 1990 ......216
Chapter II-44 Zanussi—Susegana and Porcia Plants, Italy, 1991 .......219
Chapter II-45 American Steel Service Center (ASSC), Kent,
WA, 1992 ..................................................................225
Chapter II-46 Mazak Corp., U.S., Florence, KY, 1992 ..................229
Chapter II-47 Americold, Gullman, AL, 1999 ..............................232
Chapter II-48 Sentrol, Inc., Portland (Tigard), OR, 1992 ............237
Chapter II-49 DeAcero, Monterrey, México, 1998 ........................244
Chapter II-50 OPW Fueling Components Division of Dover
Corp, Cincinnati, OH, 1993 ....................................247
Chapter II-51 Wheelabrator, LaGrange, GA, 1992–93 .................257
Chapter II-52 Alaris Medical Systems, San Diego, CA and
Tijuana, Mexico, 1999 .............................................261
Chapter II-53 Rotary Lift, Madison, IN, 1993 ..............................273
Chapter II-54 Rotary Lift, Madison, IN, 1999 ..............................275
Chapter II-55 Shade Foods, New Century, KS, 1999 ....................281
Chapter II-56 Sonic Innovations, Salt Lake City, UT, 1998 .........288
Chapter II-57 Precor, Bothel, WA, 1994 ........................................292
Chapter II-58 Goulds Pumps, Seneca Falls, NY, 1993 ..................299
Chapter II-59 Genie Industries, Redmond, WA, 1994 .................307
Chapter II-60 Marlow Industries, Dallas, TX, 1999 ......................311
Chapter II-61 MEMC Electronic Materials, St. Peters, MO, 1999 ..........316
viii • Contents
Chapter II-62 Wainwright Industries, St. Peters, MO, 1999 ......322
Chapter II-63 Prolec/GE, Monterrey, México, 1998 ...................331
Chapter II-64 Dixie Products, Business Unit of James River
Corp, Fort Smith, AR, 1990 ..................................333
Chapter II-65 Amoco Polymers, Alpharetta, GA, 1998 .............336
Chapter II-66 Intermec Co., Everett, WA, 1998 ..........................340
Chapter II-67 Foxboro Corp., Intelligent Automation
Division, Invensys plc, Foxboro, MA, 1999. ........345
Chapter II-68 Plamex, Tijuana, México – 1995, 1998.................349
PaRT III advances and Missteps along
Process-Improvement Pathways in the 2000s
Chapter III-69 Gillette Andover Manufacturing Center
(AMC), Andover, MA, 2000 .................................355
Chapter III-70 Mark Andy Co., St. Louis, MO, 2001 ...................361
Chapter III-71 Mallinckrodt, Irvine, CA, 2000 ...........................368
Chapter III-72 Lozier Corp., Omaha, NE, 2001 ...........................376
Chapter III-73 Olympus (Shenzhen) Industrial Ltd.,
Shenzhen, China, 2003 .........................................381
Chapter III-74 Woodhead de México, Cd., de Juárez, 2001 ........387
Chapter III-75 System Sensor de México, Cd. Juárez, 2001 ........390
Chapter III-76 Quadrant Homes, Bellevue, WA, 2002 ................395
Chapter III-77 Ultraframe, Clitheroe, U.K., 2008 .......................398
Chapter III-78 R.W. Lyall, Corona, CA, 2000 ..............................403
Chapter III-79 Fender Musical Instruments, Corona, CA, 2001 ......412
Chapter III-80 Ford Stamping and Assembly, Hermosillo,
México, 2011 ..........................................................419
Chapter III-81 Volkswagen, Puebla, México, 2001 ......................426
Contents • ix
Chapter III-82 Graco, Inc., Minneapolis, 2003 ............................429
Chapter III-83 Fluke Corp., Everett, WA, 2003 ............................434
Chapter III-84 TVS Motor Co., Hosur, Tamil Nadu,
India, 2012 .............................................................438
Chapter III-85 Takata Seat Belts (TSB), Monterrey,
México, 2004..........................................................446
Chapter III-86 Schweitzer Engineering Laboratories (SEL),
Pullman, WA, 2003 ...............................................457
Chapter III-87 Milliken Industrials, Wigan, U.K., 2002 .............465
Chapter III-88 Lenovo, Shanghai Area, China, 2008 ..................469
Chapter III-89 Nintendo Distribution Center, North Bend,
WA, 2008................................................................475
Chapter III-90 American Sheet Metal (ASM) and American
Integration Technologies (AIT), Chandler,
AZ, 2003 ................................................................479
Chapter III-91 SABMiller, plc, Krakow, Poland, 2008 .................485
Chapter III-92 Hollister Inc., Stuarts Draft, VA, 2009 ................490
Chapter III-93 Motores John Deere, S.A. de C.V.,
Torreón, México, 2004 ..........................................497
Chapter III-94 FCI, Cd. Juárez, Chihuahua, México, 2004 .........503
Chapter III-95 GBC Scientific Instruments, Melbourne,
Australia, 2004 ......................................................507
Chapter III-96 O.C. Tanner Co., Salt Lake City, UT, 2003 .......... 510
Chapter III-97 AmorePacific, Suwon, Korea, 2003 ...................... 514
Chapter III-98 Boeing 737, Renton, WA – 2010............................518
Chapter III-99 Gleason Corp., Rochester, NY, 2011.....................528
Chapter III-100 BMW Engines, Steyr, Austria, 2011 .....................532
Chapter III-101 ElectroImpact, Inc., Mukilteo, WA, 2014 ............534
Annotated Bibliography .....................................................................539
Index ....................................................................................................545