Art Byrne, Wiremold's CEO, introduced many innovative solutions that helped the company reach its goals of reducing costs and increasing productivity. Byrne demonstrated an excellent understanding of how to get the whole team involved in this lean manufacturing case. Byrne encouraged the team to learn from each other while implementing the changes and included everyone in the kaizen process.
He established a lean program to track the flow of parts throughout the manufacturing process. He also introduced several tools to reduce waste, increase productivity, and improve efficiency. He introduced a laser cutting machine that enabled small batches to be produced, saving money on tooling. His success was due to a lean strategy that only involved a few simple steps.
He also implemented a just in time (JIT) manufacturing process. The company could deliver vehicles in a very short time frame thanks to this manufacturing method. It also enabled harmony during manufacturing, which was key for reducing waste.
During the recession, he embraced problem-solving ideas and introduced a tool maintenance strategy that helped the company save $2 million. He also implemented an early retirement plan for unionized workers. These moves transformed Wiremold's inefficient, chaotic company into a Lean-oriented business.
He created a system that monitors the flow and quality of raw materials in the manufacturing process. He also implemented a brand new ERP system. He made sure all his team members understood the importance respecting their employees. His lean strategies were simple and effective, allowing him to make sure all employees understood the concept of kaizen. His management style fostered respect for employees and encouraged a hands-on approach.
His best asset was his knowledge of the kaizen process. He had spent time at Danaher Corporation, and he understood that a good kaizen involves the three P's: people, process and product. He also took small steps to lay off salaried employees. He used his kaizen strategy to ensure his team accomplished their tasks.
He also introduced the concept of value stream mapping. This is a diagram which shows how manufacturing resources impact the overall efficiency of a company. He also introduced the concept of a Kaizen event worksheet, which can be used to track key improvement activities. A chart that shows overall achievements displays the results.
He also created a system for reducing lead times, which is crucial for the manufacturing industry. The company's fine blank machines produced 600-800 blades an hour. It eliminated the need of a lot manual labor. The kanban card is another tool that was used for reducing lead time.
Wiremold was a leader in conduit casing manufacturing. After the company underwent a major overhaul under Art Byrne, sales skyrocketed from 100 million dollars to 450 million dollars in just ten years. French competitor Legrand purchased the company in 2001. However, Wiremold's journey was not always successful. Its biggest problem was queue processing, which left designated stations with too much or too little work.
FAQ
Is it possible to automate certain parts of manufacturing
Yes! Yes. Automation has been around since ancient time. The Egyptians invented the wheel thousands of years ago. To help us build assembly lines, we now have robots.
In fact, there are several applications of robotics in manufacturing today. These include:
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Assembly line robots
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Robot welding
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Robot painting
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Robotics inspection
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Robots create products
Automation can be applied to manufacturing in many other ways. 3D printing is a way to make custom products quickly and without waiting weeks or months for them to be manufactured.
How can we improve manufacturing efficiency?
The first step is to identify the most important factors affecting production time. The next step is to identify the most important factors that affect production time. If you don’t know how to start, look at which factors have the greatest impact upon production time. Once you've identified them all, find solutions to each one.
Why is logistics important in manufacturing
Logistics are essential to any business. They enable you to achieve outstanding results by helping manage product flow from raw materials through to finished goods.
Logistics play a key role in reducing expenses and increasing efficiency.
What is the distinction between Production Planning or Scheduling?
Production Planning (PP) refers to the process of determining how much production is needed at any given moment. This can be done by forecasting demand and identifying production capabilities.
Scheduling refers the process by which tasks are assigned dates so that they can all be completed within the given timeframe.
Statistics
- According to the United Nations Industrial Development Organization (UNIDO), China is the top manufacturer worldwide by 2019 output, producing 28.7% of the total global manufacturing output, followed by the United States, Japan, Germany, and India.[52][53] (en.wikipedia.org)
- According to a Statista study, U.S. businesses spent $1.63 trillion on logistics in 2019, moving goods from origin to end user through various supply chain network segments. (netsuite.com)
- Job #1 is delivering the ordered product according to specifications: color, size, brand, and quantity. (netsuite.com)
- It's estimated that 10.8% of the U.S. GDP in 2020 was contributed to manufacturing. (investopedia.com)
- [54][55] These are the top 50 countries by the total value of manufacturing output in US dollars for its noted year according to World Bank.[56] (en.wikipedia.org)
External Links
How To
How to Use lean manufacturing in the Production of Goods
Lean manufacturing is a management style that aims to increase efficiency and reduce waste through continuous improvement. It was created in Japan by Taiichi Ohno during the 1970s and 80s. He received the Toyota Production System award (TPS), from Kanji Toyoda, founder of TPS. The first book published on lean manufacturing was titled "The Machine That Changed the World" written by Michael L. Watkins and published in 1990.
Lean manufacturing is often described as a set if principles that help improve the quality and speed of products and services. It emphasizes the elimination and minimization of waste in the value stream. Just-in-time (JIT), zero defect (TPM), and 5S are all examples of lean manufacturing. Lean manufacturing focuses on eliminating non-value-added activities such as rework, inspection, and waiting.
Lean manufacturing not only improves product quality but also reduces costs. Companies can also achieve their goals faster by reducing employee turnover. Lean manufacturing can be used to manage all aspects of the value chain. Customers, suppliers, distributors, retailers and employees are all included. Lean manufacturing practices are widespread in many industries. Toyota's philosophy is the foundation of its success in automotives, electronics and appliances, healthcare, chemical engineers, aerospace, paper and food, among other industries.
Lean manufacturing includes five basic principles:
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Define value - Find out what your business contributes to society, and what makes it different from other competitors.
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Reduce Waste - Remove any activity which doesn't add value to your supply chain.
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Create Flow: Ensure that the work process flows without interruptions.
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Standardize and simplify - Make your processes as consistent as possible.
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Build Relationships- Develop personal relationships with both internal as well as external stakeholders.
Although lean manufacturing has always been around, it is gaining popularity in recent years because of a renewed interest for the economy after 2008's global financial crisis. Many businesses have adopted lean manufacturing techniques to help them become more competitive. In fact, some economists believe that lean manufacturing will be an important factor in economic recovery.
Lean manufacturing, which has many benefits, is now a standard practice in the automotive industry. These include improved customer satisfaction, reduced inventory levels, lower operating costs, increased productivity, and better overall safety.
Any aspect of an enterprise can benefit from Lean manufacturing. This is because it ensures efficiency and effectiveness in all stages of the value chain.
There are three types of lean manufacturing.
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Just-in-Time Manufacturing (JIT): This type of lean manufacturing is commonly referred to as "pull systems." JIT means that components are assembled at the time of use and not manufactured in advance. This approach reduces lead time, increases availability and reduces inventory.
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Zero Defects Manufacturing (ZDM): ZDM focuses on ensuring that no defective units leave the manufacturing facility. If a part is required to be repaired on the assembly line, it should not be scrapped. This applies to finished products, which may need minor repairs before they are shipped.
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Continuous Improvement (CI),: Continuous improvement aims improve the efficiency and effectiveness of operations by continuously identifying issues and making changes to reduce waste. Continuous Improvement (CI) involves continuous improvement in processes, people, tools, and infrastructure.