Relentless Improvement: True Stories of Lean Transformations

235 Pages·2012·3.37 MB·English

by  Bill Trudell

Business & Management / Lean Methods & Implementation
A P R O D U C T I V I T Y P R E S S B O O K
RELENTLESS IMPROVEMENT
TRUE STORIES OF LEAN TRANSFORMATIONS
Tracing the author’s decades-long continuous improvement journey, Relent-
less Improvement: True Stories of Lean Transformations walks readers
through vivid shop floor experiences to convey a genuine feel for the environ-
ments in which Lean Six Sigma transformations occur. Recounting numerous
Lean Six Sigma transformations, it illustrates the spectrum of successful
operational tactics. TRUE STORIES OF LEAN
The story starts just outside Detroit, Michigan in the 1970s when the auto
industry was booming, and most people in the area worked in the car TRANSFORMATIONS
factories, or in one of the component factories that supplied the Big Three.
The complexity and detail of the projects grow chapter by chapter. The book
begins by explaining how to manage Lean basics such as applying 5S,
shortening product cycle times, and creating standard work. It then B i l l T r u d e l l
progresses to factory Lean Six Sigma transformations. Providing implementa-
tion guidance geared to functions on the operational level, the book:
• Presents stories based on the author’s interactions with company
leaders and shop-floor employees in the midst of great change
• Illustrates real-world plant politics and manufacturing situations using
compelling stories
• Highlights valuable lessons learned at the end of each chapter
Using an engaging story format, the book recounts the author’s career
experiences to provide you with a real-world understanding of how to
use Lean tools. The stories in the book illustrate everything from standard
work and takt time to Kaizen events and Total Productive Maintenance.
The text also includes accounts of “front end” or administrative processes
such as product development and materials handling.
K15311
Trudell RELENTLESS IMPROVEMENT TRUE STORIES OF LEAN TRANSFORMATIONS
TRUE STORIES OF LEAN
TRANSFORMATIONS
TRUE STORIES OF LEAN
TRANSFORMATIONS
B i l l T r u d e l l
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A P R O D U C T I V I T Y P R E S S B O O K
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2013 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20121030
International Standard Book Number-13: 978-1-4665-5431-3 (eBook - PDF)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts
have been made to publish reliable data and information, but the author and publisher cannot assume
responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize to
copyright holders if permission to publish in this form has not been obtained. If any copyright material has
not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmit-
ted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented,
including photocopying, microfilming, and recording, or in any information storage or retrieval system,
without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.
com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood
Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and
registration for a variety of users. For organizations that have been granted a photocopy license by the CCC,
a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used
only for identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Dedication
As a father, I have been blessed at the highest level.
I dedicate this book to my four children
Leslie, Adam, Cayman, and Harrison. Being your father
is and has been an incredible experience, and I am as
proud as I can be of each and every one of you.
—Dad
v
Contents
Introduction ........................................................................................ xiii
Chapter 1 A Manufacturing Family ................................................... 1
Lessons Learned ......................................................................8
Chapter 2 My First Factory ................................................................. 9
Lessons Learned ................................................................... 20
Chapter 3 Maybe Not Lean, But Lean Things ................................. 21
Do It Right the First Time ........................................................22
Product Development ...............................................................23
Problem Solving .........................................................................24
Takt Time ...................................................................................25
Standard Work ...........................................................................26
Lessons Learned ....................................................................27
Chapter 4 My First Process Improvement Project .......................... 29
Leadership Nirvana ...................................................................32
Lessons Learned ....................................................................33
Chapter 5 Process Improvement Project #2 ..................................... 35
Te New Owners Are at the Gate ............................................36
Lessons Learned ................................................................... 43
Chapter 6 My Lean Journey Begins .................................................. 45
Water Spiders .............................................................................51
Te Building Is on Fire .............................................................53
Hazardous Spill ......................................................................... 54
Lessons Learned ....................................................................55
vii
viii  •  Contents
Chapter 7 Outboard Marine Corporation — Marine Power
Products Group ................................................................ 57
Marine Power Product Group Purchasing ............................59
Getting to Know the Gemba: Te Product and the People ...62
OMC–Burnsville...................................................................62
OMC – Calhoun .................................................................. 64
Lessons Learned ................................................................... 66
Jet Skis ........................................................................................ 66
Lesson Learned .................................................................... 68
Cylinder Sleeves ........................................................................ 68
Lessons Learned ....................................................................70
More Standard Work ................................................................71
Lessons Learned ....................................................................72
Chapter 8 Japan .................................................................................. 73
Mr. Yamata ............................................................................76
Are You Sure He Is Not Mad at Me? .............................79
Closing Out the Audit ......................................................... 80
Mouth Test .............................................................................81
Lessons Learned ....................................................................81
Multi-Plant Inventory Reduction ............................................82
Lesson Learned .................................................................... 84
Bearing Shortage ...................................................................... 84
Lesson Learned .....................................................................85
Stickle Bricks: One-Piece Flow ................................................85
Afnity Diagram ...................................................................... 86
Lesson Learned .....................................................................89
Te War Room ...........................................................................89
Lesson Learned .....................................................................91
Te Project Continues… ..........................................................91
Design for Manufacture and Assembly ..................................93
Proven Technology versus High-Tech ....................................94
Lesson Learned .....................................................................95
Competitive Product Comparison Project:
Boston Consulting Group ........................................................95
Lesson Learned .................................................................... 96