Published By:
Society of Manufacturing Engineers

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Published: Feb 17, 2005
Length (hr:min): 00:22

Description:
Starting with an explanation of why a company should keep its manufacturing areas clean, this program shows you an actual 5S training event at two different manufacturing companies. 5S stands for Sort out, Set in order, Shine, Standardize, and Sustain. You will see a 5S Factory Makeover of Symmons Industries in Braintree, MA., and at Affordable Interior Systems in Hudson Massachusetts. Recorded during training classes on 5S, you will see the kinds of things that were changed to improve productivity and make the work simpler and easier. The clean up teams are first taught the 5S principles and are then unleashed to go forth and make improvements. The intended audience for this video is anyone in a manufacturing company that has just started to implement lean or for companies who need to revive their lean efforts.

Published By:
Society of Manufacturing Engineers

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Published: Mar 18, 2003
Length (hr:min): 00:26

Description:
Part of the Manufacturing Insights (MI) DVD series. This program explains how visual controls are developed and used in a factory environment to help identify production problems quickly. In the examples for this program you will see visual controls used to control inventory, schedule maintenance, and clearly mark machine and tool locations. Other examples show the benefits of posting key goals and the motivational effects of successful communication. This program explains what the typical worker reaction is to using visual controls, and what steps are needed to help sustain the gains received after implementation. The program also explains that the use of visual controls needs to be part of a much larger lean manufacturing effort. Several examples of visual controls are shown at different locations. Breed Technologies, a passenger restraint systems manufacturing company in Knoxville, TN, uses visual controls extensively to help map their processes. Also, Delphi Interior Automotive Systems in Adrian, MI, uses visual controls to track production rates. The Donnelly Corporation, an automotive supplier headquartered in Holland, MI, shows how they save time and increase quality by using innovative visual controls. Visual Controls are also shown at the Ford Motor Company, Romeo, MI, engine plant to improve assembly quality and employee communications.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:20

Description:
Part of the Manufacturing Insights (MI) DVD series. With Breakthrough Kaizen Events, you will experience an actual kaizen event at the Lantech Corporation. A total of over 100 improvements were completed during this event. Several new devices are demonstrated so the viewer can understand how the changes improved the process. See how they use a kaizen newspaper to keep everyone informed of any changes that are being made. Hear comments from several experienced kaizen leaders as they describe employee attitudes found in a successful event. Find out how Lantech was able to improve productivity by 12%, eliminate quality problems and solve several safety and ergonomic issues. Finally, learn the essential goals and commandments of kaizen so you can solve problems and eliminate waste with kaizen.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:38

Description:
Part of the Manufacturing Insights (MI) DVD series. This program highlights the methods used by manufacturing companies to prevent their continuous improvement efforts from fading away. An interview with Professor Clinton Longenecker provides the reason most improvement programs fail and what you can do to keep your workforce motivated to improve. Three companies that have re-energized their workforce are examined. (1) AMP Incorporated used a "treasure hunt" to uncover millions of dollars of improvements. (2) C.R. Bard realized that to sustain continuous improvement they needed to upgrade team members' people skills. (3) Walbridge Coatings found that the motivation from completing the QS 9000 quality certification process has reinvigorated their continuous improvement efforts.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:32

Description:
Part of the Manufacturing Insights (MI) DVD series. This program shows examples of how four different companies reduced changeover times to be more responsive to customer orders. The first part of the program outlines the benefits of reducing set-up times and how to identify wasted time by analyzing your current routine. Next, examples of quick changeover in plastic injection molding, metal stamping and metal cutting are explored to give the viewer an understanding of the type of equipment and procedures used during quick changeovers. The four companies are The Wiremold Company, Associated Spring, Powers and Sons, and Hitachi Automotive Products (USA). The program concludes with five common organizational procedures to follow when implementing quick changeover.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:33

Description:
This Shingo Prize-winning video program explains how value-stream mapping can be used to find waste in your production system. It starts by discussing the problems associated with a mass production philosophy. Dr. James Womack, president of the Lean Enterprise Institute, shares some of his experiences with mapping and what kind of reaction most people have when they learn to see waste within their operation. The three types of information needed to build a value-stream map are explained along with an explanation of how the timeline calculation at the bottom of the map highlights excessive inventories. Part of the Manufacturing Insights video series, this program uses an in-depth example of value-stream mapping at the Donnelly Corporation. This automotive supplier created one-piece flow, cut inventories, and made major improvements in quality and delivery by using value-stream mapping to help focus improvement efforts in the right areas. Several different future state icons are explained in detail to show how lean techniques such as kanban, flow, and supermarkets operate in real world conditions. .

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Jan 05, 2004
Length (hr:min): 00:26

Description:
Kanban is a Japanese term for a visual system used to trigger activity upstream in a given process. The most important point to remember about a Kanban system is that the best Kanban system is no Kanban system and it is only a substitute for not being able to implement single piece flow in your process. Examples of Kanban systems are shown from Carver Pump Company, Muscatine, IA, where Kanban cards, bins, and visual replenishment are used to deliver a wide variety of military and commercial pumps. A second example of Kanban is at Ariens Company, Brillion, WI, which has converted from a computer based inventory control system to using Kanban to trigger each step in the process of building snow blowers and lawn mowers. In the summary, six simple rules are presented that must be followed to make your Kanban system successful.

Published By:
Society of Manufacturing Engineers

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Published: Mar 28, 2003
Length (hr:min): 00:30

Description:
Part of the Manufacturing Insights (MI) DVD series. As products increase in complexity and processes have to be configured very quickly to hit small windows of opportunity, the implementation of a mistake proofing program, or poka-yoke, becomes a critical part of any manufacturing system. Exploring how poka-yoke is being implemented and in what direction it is leading manufacturing is the focus of this video program. Through a series of revealing and informative case studies, this video shows how several leading companies developed systems to answer key questions in the mistake proofing process.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:30

Description:
Part of the Manufacturing Insights (MI) DVD series. By viewing this program you will discover how a Six Sigma quality program has improved 3 different manufacturing organizations. Insightful interviews with both manufacturing and quality people within the various companies share their results of several of the Six Sigma programs they have run. First at Ortho Clinical Diagnostics, where they believe Six Sigma will make them number one in their industry by helping to identify, and create, permanent solutions to any manufacturing problem. Using Six Sigma problem solving techniques, a discrepancy between Ortho Clinical Diagnostics and a supplier as to the measurement specifications for an air compressor was discovered. They were able to use this information and redesign a new compressor that operated within specifications. Next at Gretag Imaging, where you will see how a photographic hardware manufacturer has improved customer satisfaction by helping to solve difficult logistical problems. The final example of Six Sigma is at Lockheed Martin's Government electronic systems plant where they've saved nearly 3 billion dollars over the last three years with a combination of Six Sigma and Lean Manufacturing programs. Lockheed has applied Six Sigma concepts throughout its entire organization being careful to align projects to strategic goals of the organization.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:31

Description:
Part of the Manufacturing Insights (MI) DVD series. This program is an introduction to Supply Chain Management. It shows how information technology is used to gather real-time data to provide meaningful management information for maintaining supplier-customer relationships. Hewlett Packard uses real-time information systems to track retail sales, allowing better customer demand forecasting and reduced product inventory. The service parts operation within the Saturn Corporation controls repair parts availability at all Saturn retailers. Their goal is to have all parts available at every Saturn retailer to keep the customer's car on the road. Detailed interviews with potential vendors have enabled Case IH to dramatically reduce finished goods inventory while providing new products to specialized customers. Additional insight into partnerships is provided through an interview with Robert Handfield from Michigan State University's Department of Marketing and Supply Chain Management.

Published By:
Society of Manufacturing Engineers

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Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 18, 2003
Length (hr:min): 00:26

Description:
Part of the Manufacturing Insights (MI) DVD series. This program will show you case studies from 4 companies who have successfully implemented lean tooling, PLUS learn specifically what you can do to be more like those companies. Lee Blake Precision Machining shows how they've integrated lean tooling into their daily work practices, saving a tremendous amount of time and money. Eaton Aerospace shows how the 5S System and Visual Controls were used as they implemented lean tooling. K&A Machine & Tool, where a KANBAN system was used to control tooling insert usage. Classic Turning, where employees are solving tooling and changeover problems through teamwork and continuous improvement. Lean Tooling practices can bring immediate and powerful results - learn how to implement it at your facility. This program is meant to be used in conjunction with the Introduction to Lean Tooling program, which presents the five phases of implementing Lean Tooling.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Sep 13, 2004
Length (hr:min): 00:19

Description:
This new video program will show you how the VHS duplicator TECHNICOLOR Company was able to tap into the power of employee ideas to help their business thrive by building employee trust. Like so many organizations, TECHNICOLOR, located in Livonia, Michigan, was facing competitive pressures, and had to improve their performance or be eliminated. By motivating the employees to come up with ideas to make them more efficient, they were able to effect a positive change in their workplace culture and gain market share in the VHS duplication business. Examples are based on improvements in facilities layout, improved visual controls, elimination of a noise problem, reduction of tape handling and other smaller wastes. By viewing this program you will hear some of the actual ideas that were submitted, from the actual people who came up with the ideas. You will also hear a description of the system in place at TECHNICOLOR that collects and implements these employee ideas.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Apr 30, 2003
Length (hr:min): 00:40

Description:
This Manufacturing Insights video demonstrates how predictive and preventive maintenance techniques can bring an end of crisis maintenance. The video shows how TPM keeps equipment operating at design specs, and gets more output from smaller facilities. A case study at Delco Remy shows how increases in productivity were gained through teamwork, training, and a sophisticated Computerized Maintenance Management System. A second case study at Loran Cassettes and Audio Products shows how a small manufacturer who is a Q-1 certified supplier, successfully executes TPM techniques. Since implementing its TPM program in mid-1990, daily downtime fell by 29%, daily defects decreased by 22%, and production increased by 20%. The last case study is at Miller Brewery's Packaging Plant where a reliability engineer on staff is responsible for identifying and eliminating recurring problems through equipment redesign or modification.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: May 08, 2003
Length (hr:min): 00:24

Description:
Part of the Manufacturing Insights (MI) video series, recorded at the Lean Learning Center in Novi, Michigan, this program lets you experience a lean transformation simulation during a week-long educational course. Experience a realistic lean experiment without high cost, or any risk of failure. Observe the different methods each team applied to solve a similar problem. Learn how lean is a process of improvement, not just predetermined tools. See how people found opportunities for significant improvement in their processes. Viewing this program will show you how people like yourself applied lean principles and rules to increase efficiency, improve quality, and strengthen customer-supplier connections. You'll also learn about systematic waste elimination, what it means to establish high agreement within your work group, and four key lessons that everyone should apply to their lean transformation efforts.

Published By:
Society of Manufacturing Engineers

Product Information:
Published: Mar 01, 2005
Length (hr:min): 00:30

Description:
Design for Manufacture and Assembly (DFMA) is a proven design methodology used to optimize part costs and quality, while reducing time-to-market development. This program features an interview with Nicholas Dewhurst of Boothroyd Dewhurst and explains the concepts and use of DFMA in product analysis to understand the drivers of cost, and the interaction of the individual pieces within the product to optimize design, manufacturability, and assembly. Two companies who have successfully used DFMA are also highlighted, including: MDS-SCIEX, a scientific instrumentation manufacturer, where implementation of DFMA philosophies helped reduce the product development design cycle for their API 2000 mass spectrometer from 48 months to 16 months. Plug Power, a fuel cell manufacturer, where the integral use of DFMA facilitated development of their Proton Exchange Membrane fuel cell systems at the lowest cost while emphasizing three key elements: system manufacturability, serviceability, and sustainability.