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ASSEMBLY Assembly Plant of the Year Technology Drives Kenworth to Excellence
ost people traveling along build products faster, better and more Assemblers at Kenworth’s an interstate highway at 70 efficiently than its competition. Renton, WA, factory use mph assume that all trucks Kenworth views itself not as a truck look the same. But, many company that uses technology, but high-tech tools to build commercial drivers would rather as a high-technology company Mbeg to differ. They claim that builds trucks. Employees at the world-class trucks. that one truck stands out among all the 270,000-square-foot Renton plant are rest: Kenworth. The 81-year-old brand using a variety of leading-edge tools to is considered by many truckers to be the improve operating efficiency and boost “world’s best.” bottom-line profitability. Vehicles “The plant strives to lead not only made by Ken- within our company, but also within the worth Truck Co. industry as a whole,” says Doug Baugh, Assembly (Kirkland, WA) are plant manager. “Our focus is an initia- known for their relia- tive called break-through performance, bility, durability and which is characterized by ‘possibility dependability. Whether thinking.’” Plant hauling perishable vegeta- “Possibility thinking encourages us Year bles across country or a load of to look inside and outside the industry of the cement around town, the red and to determine better ways to conduct our white KW logo on the front grill business,” adds Joe Zitzelberger, symbolizes quality to truckers. director of manufacturing development. Quality, pride and passion go into “The end result is to implement means 2004 each truck that rolls down Kenworth’s or methods to increase truck quality assembly line in Renton, WA. The through continuous improvement. To 11-year-old facility is the recipient of help gauge our industry leadership, over ASSEMBLY magazine’s inaugural 16 major benchmarking studies were Assembly Plant of the Year award. It was conducted in the past year alone.” nominated for its innovative use of infor- Because of its product innovation mation technology to reduce production and reliability, Kenworth is recognized costs, increase productivity, improve as the industry leader for heavy-duty safety, shorten time to market, and trucks. In fact, this year, the company enhance product quality and yields. received the prestigious J.D. Power and Kenworth, a division of PACCAR Associates award for highest ranking in Inc. (Bellevue, WA), has been customer satisfaction among vocational aggressively applying information segment Class 8 truck owners. technology to improve the way it Kenworth traces its roots to 1923, assembles custom-engineered, build- when Seattle entrepreneurs Harry Kent to-order trucks. The company has and Edgar Worthingon developed a By Austin Weber developed and implemented a variety of rugged four-cylinder “Western truck Senior Editor high-tech tools on the plant floor to for Western work,” such as climbing 38 ASSEMBLY / November 2004 www.assemblymag.com 38_asb1104plantofyear3.qxd 10|14|04 11:50 Page 39
For more than 80 years, Kenworth vehicles have been a common sight on the highways and byways of America. Photo courtesy Kenworth Truck Co. steep hills and traversing mountain business is very competitive, because Assemblers in Renton build a wide forests. In 1933, Kenworth became the trucking is a cyclical industry. But, after variety of trucks, such as aerodynamic first American truck manufacturer to several lackluster years, business is models with sleeper cabins for long- install diesel engines as standard equip- picking up due to the improving U.S. haul applications; models with good ment. The company also developed the economy. visibility and maneuverability for short industry’s first sleeper cabs. According to Standard & Poor’s haul and urban delivery; and heavy- Kenworth was acquired by PACCAR (New York), demand for heavy-duty duty vocational models that are used as in 1944. Today, the $11 billion company trucks is up 40 percent this year. Global cement mixers and dump trucks. also owns Peterbilt Motors Co. (Denton, Insight Inc. (Waltham, MA) reports that “The Renton plant has the ability to TX), in addition to several leading truck orders for heavy trucks exceeded manage an incredible variety of manufacturers in Europe, such as DAF, 96,000 units during the first three product,” says Dave Stevens, director of Foden and Leyland. months of 2004, the best three-month manufacturing engineering. “The plant PACCAR will be celebrating its cen- performance since early 1998 and more handles the maximum variation of our tennial next year. The company was than double year-earlier levels. In fact, product line. Today, the fluctuation in originally called Pacific Car and PACCAR reported record revenues and content is greater than ever. And, vehicle Foundry, and was a leading manufactur- net income for the first half of 2004. technology is more challenging.” er of railroad rolling stock, such as refrig- Replacement demand has been driving For instance, Stevens says vehicles erated cars used for transporting fruit. the market. now use a vast array of sophisticated The Kenworth Renton plant is located on Swift Transportation Co. (Phoenix) electronics. Kenworth trucks can be the site of the company’s former railcar recently ordered several thousand equipped with navigation systems, factory, which closed in 1988. Kenworth trucks for its large fleet. In satellite radio, collision avoidance addition, Kenworth is currently pro- warning systems, night vision systems Competitive Market cessing a large order from Costco and stability control braking systems, The trucking industry is the back- Wholesale Corp. (Issaquah, WA). To making the assembly process more bone of the U.S. economy. In fact, the meet that growing demand, the Renton complex. American Trucking Associations assembly line has seen steady produc- “The data infrastructure required to (Alexandria, VA) claims that profes- tion increases. handle these systems, and communicate sional truck drivers account for 68 per- The Renton facility builds most of with electronic control modules of major cent of all freight delivered in the the trucks in the Kenworth product line. systems, is very sophisticated,” explains United States. Many of those items The other trucks are produced at Stevens. “Testing of electronics for arrive with Kenworth vehicles. Kenworth plants in Chillicothe, OH, St. reliability and interference is increasingly The Class 8 truck manufacturing Therese, QE, and Mexicali, Mexico. important, because so many systems, www.assemblymag.com November 2004 / ASSEMBLY 39 38_asb1104plantofyear3.qxd 10|14|04 11:50 Page 40
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to the cab electrical system while it to be the industry’s most classic the cab is still on the trim line. design. Many customers usually spec “This allows us to do a functional their vehicles with stainless steel and test of all gauges, switches and polished chrome options. lights to ensure the cab is ready for In addition to over-the-road mod- setting onto the chassis,” says els, Kenworth is a leading manufactur- Stevens. “The tester prompts the er of off-highway trucks that are made operator through a function vali- for transporting heavy loads of com- dation sequence and generates a modities, such as coal or timber, in chassis-specific test report.” Infor- remote locations. Kenworth also has a mation is also stored in a database long heritage of building trucks that that can be used for statistical haul equipment used for servicing oil analysis. fields in severe climates and terrain, ranging from Siberian tundra to Saudi High-Mix Assembly Line Arabian sand dunes. Kenworth vehicles assembled Many off-road trucks are equipped at the Renton plant include the: with special options, such as tandem T600. This aerodynamic steering, six-wheel drive, tubular long-haul tractor is aimed at fleets bumpers, brush guards, extra fuel tanks eager to cut fuel consumption. and roof-mounted beacons, in addition T800. This truck features to raised fuel tanks and brake chambers a set-back front axle to opti- for greater ground clearance. mize payload potential and Because of the large size and unique Many customers spec their trucks with stainless steel and maneuverability. This popular requirements of these trucks, the polished chrome options. Photo courtesy Kenworth Truck Co. vehicle accounts for more than Renton plant builds them in a dedicated from the engine to the transmission to the 50 percent of the plant’s production. area of the factory. Kenworth offers two brakes, are electronically controlled.” W900. This vehicle, featuring tra- basic types of off-highway trucks, Engineers recently developed a cab ditional long-nosed styling, is popular including the: harness electrical tester that is connected with independent truckers who consider C500. These trucks are designed About the Award
The ASSEMBLY magazine “Assem- Have assembly processes been Has the plant taken steps to reduce bly Plant of the Year” award was initiat- improved through the use of new production costs? ed earlier this year to showcase world- technology? Have new or improved assembly class production facilities in America, Has the plant improved its perfor- processes resulted in increased pro- and the people, products and processes mance by making more effective use of ductivity? that make them successful. All manu- existing technology? Has the plant used assembly improve- facturers that assemble products in the ments to reduce time to market? United States were invited to nominate Has the plant boosted bottom-line their plants. profits and competitive advantage? The goal was to identify a state-of-the- Did operators play a role in the suc- art facility that has applied world-class cessful implementation of new assembly processes to reduce production cost, strategies? increase productivity, shorten time to Has a product been effectively market or improve product quality. designed for efficient assembly? An official nomination form was print- Has the plant attempted to protect the ed in several issues of ASSEMBLY; in environment and conserve natural addition, an online version appeared on resources? the magazine’s Web site (www.assembly- As winner of the inaugural Assembly mag.com). Nominations were received Plant of the Year competition, Kenworth from a diverse group of manufacturers that Truck Co. (Renton, WA) received an reflect the magazine’s demographics. engraved crystal award during a special All nominees were evaluated by a presentation at the recent Assembly group of independent experts and by Technology Expo in Chicago. In addi- ASSEMBLY’s editorial staff, based on tion, Kenworth received a commemora- the following criteria: tive banner to display inside its plant.
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prices, a shortage of qualified drivers and driver retention. To address these issues, Kenworth engineers are con- stantly searching for new innovations that help customers gain life-cycle cost advantages and retain drivers. For instance, the company recently launched a lightweight rear-axle air-ride suspension system. The proprietary design produces a smoother ride and reduces maintenance. Kenworth has also introduced extended cabs for its popular T600, T800 and W900 vehicles. The new cabs increase interior space by 15 percent, which enhances driver comfort and provides additional storage space. To maintain a competitive edge, Kenworth invests heavily in research and development. In fact, the company Kenworth trucks are known for their reliability, durability and dependability. Photo courtesy recently opened a state-of-the-art R&D Kenworth Truck Co. center next to the Renton assembly for hauling heavy loads in both on- and feature large sand tires and heavy-duty plant. Engineers use rapid prototyping off-road conditions. axles, chassis and components. and a five-axis router to help speed the 953. These extra-large trucks are No matter what type of vehicle they design process, enabling product built for demanding off-road desert order, all truck operators are faced with enhancements 12 to 24 months faster applications and extreme payloads. They the same challenges, such as rising fuel than 10 years ago.
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Sister Plant Is Also Impressive Kenworth Truck Co. (Kirkland, WA) a result, it takes nearly 50 percent less labor To ensure predictable delivery to the owns two assembly plants in the United to assemble the cab-sleeper structure of a customer, the plant introduced a new met- States. In addition to its facility in Renton, T2000, compared to the previous model. ric in 2003 that measures the time from WA, which is the recipient of the inaugur- The Chillicothe plant uses an employee- scheduled chassis start to delivery at the al ASSEMBLY magazine Assembly driven safety program to increase aware- transport company. Kenworth has set a Plant of the Year award, the company ness and eliminate unsafe actions. A volun- target of 3 days for this turnaround. Last operates a plant in Chillicothe, OH, that is tary steering committee for the program is year, systems improvements resulted in bigger, older and equally impressive. made up entirely of plant employees who an 18 percent reduction in warranty cost. The 30-year-old plant boasts more than set the program’s goals and direction. Since The plant also has implemented 335,000-square-feet of space. More than the program’s inception in 2001, the plant numerous initiatives to reduce in-house 1,440 people work in the nonunion facility. has seen a 29 percent decrease in work- inventory and increase inventory turns. The plant produces many of the same vehi- related injuries and illnesses. In 2003, the main warehouse was elimi- cles as Renton, in addition to the T2000, the Employees also conduct quality audits nated and additional docks were added newest Kenworth model. The truck blends on a representative sample of completed as the plant moved toward one-touch weight-saving components, options and trucks, using a weighted scoring system. material handling. Inventory turns materials with leading-edge aerodynamics. Evaluation results are monitored daily and increased by 14 percent last year. For instance, it uses 20 percent fewer parts corrective actions are immediately fed back During the past year, the Chillicothe than other Kenworth models. to operators. Quality is validated three plant has integrated Six Sigma principles. The T2000 is built using an automated times annually via a product audit. During These efforts have yielded a 6 percent assembly fixture, a robotic adhesive appli- the past 3 years, there has been a 50 percent improvement in per truck assembly effi- cation system and an RFID-controlled con- improvement in scores. At the same time, ciency and a 46 percent reduction in per veyance system for assembly of the cab the plant has shifted its focus from “inspect- truck scrap. “While the numbers are structure. “Design and manufacturing part- ing in” quality to making quality the impressive, it is truly the flexibility and nered to develop this extremely efficient responsibility of every employee. As a dedication of the Kenworth Chillicothe assembly process,” says Joe Zitzelberger, result, the number of quality assurance per- workforce that has made these results pos- director of manufacturing development. As sonnel has decreased by 33 percent. sible,” says Zitzelberger.
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Initial frame assembly
Final frame assembly
Chassis paint booth
Engine prep and installation
Final assembly line
Test and inspection
Hood trim
Sleeper trim
Cab trim
Cab build
Sleeper build
Paint shop
Off-highway assembly line
Employees build more than 30 trucks per day at the 270,000-square-foot Renton plant. Photo courtesy Kenworth Truck Co. The new facility also features a “Truck deliveries and unloading are requirements. Every vehicle is custom- design-visualization room where scheduled down to the minute, so if a dri- engineered, from bumper to taillight. engineers wear special 3D goggles to ver shows up late, it costs everyone Each truck is built any way customers view real-sized images of trucks money,” says Bechtold. “That’s why run- want it, with multiple configurations to projected on a 16-by-20-foot screen. ning a reliable truck is so important—it choose from. Engineers can rotate or flip the virtual helps maximize uptime and productivity, “We use a production process that truck, or peer at it from any angle, to test and minimize unexpected repairs.” enables any model to be produced at new designs and evaluate potential any time, as opposed to a batch assembly challenges. Custom-Built Vehicles process,” says Zitzelberger. “Every “Trucking is a very competitive Kenworth prides itself on providing truck coming down the assembly line is business, so our customers demand trucks that meet each customer’s unique different. Customers specify many higher reliability from our products,” different options to meet their says Jim Bechtold, chief engineer. “Our application. This means that the design engineers not only work on new assembly teams need to be well trained products, but on ways to make existing and adapt to the changing assembly products more productive and reliable. requirements.” Engineering for reliability is a Zitzelberger claims that Kenworth philosophy that filters down from the offers more job-specific, factory- very top at Kenworth, to the people who installed options than any other manu- actually assemble the truck.” facturer. Customers can also select Earlier this year, the Federal Motor add-on features, such as pusher axles Carrier Safety Administration (Wash- and hydraulic tanks. ington, DC) implemented a new hours- Sleepers range from 38-inches to 86- of-service rule that makes dependable inches, each equipped with numerous uptime more important than ever. interior appointments and features. In Under the new rules, the clock starts addition, there is a wide variety of ticking as soon as drivers go on duty and chrome and polish options, such as continues counting up to 14 hours, polished battery boxes, tool boxes, fuel whether they are driving or waiting at a tanks and exhaust stacks. loading dock. This puts more pressure Tablet PCs are used on the plant floor to capture “Given the custom product expected on drivers and their equipment to make accurate production information and make by our customers, the integration of engi- on-time deliveries. better business decisions. Photo by Austin Weber neering and plant floor technologies is a 44 ASSEMBLY / November 2004 www.assemblymag.com 38_asb1104plantofyear3.qxd 10|14|04 11:51 Page 46
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receive details of the order over an elec- tronic network. Axles, engines, frames, radiators, seats, tires and other compo- nents are sequenced and delivered sever- al times a week to minimize inventory. In 2003, production lead time was 5 to 8 weeks from point of order to point of delivery. Production time is based on customer demand, current market conditions and order backlog. Each step is evaluated for non-value- added activities using Six Sigma methodologies. One-touch material handling practices, starting with shipments from suppliers, have led to record efficiencies, such as a 13 percent reduction in material handling hours. Warehousing space within the Renton plant has been reduced by 71 percent, freeing up floor space for value-added Kenworth also builds trucks for demanding off-road applications such as logging (above) and oil activities. “The relationships and field service (below). Photos courtesy Kenworth Truck Co. partnering with our suppliers are an must,” says Zitzelberger. “We build 10 and brand of diesel engine, are trans- inherent part of our success story,” different truck models. The manufactur- mitted electronically to the Renton claims Baugh. ing engineering groups work closely plant, where engineers review the A material logistics planning system with employees and our information order. Kenworth engineers often sug- allows ordering by standard quantities. technology group to identify methods gest a different component, such as a Use of returnable containers allows for that enhance plant performance.” specific transmission, to better suit the more efficient use of trailer space and The assembly process begins when customer’s intended use. line-side part presentation. a buyer selects features at one of 281 Once the order is approved, Kenworth “This is allowing more material to be Kenworth dealerships in the United suppliers, such as Caterpillar Inc. (Peoria, delivered line-side, reducing the need States. Specifications, such as the size IL) and Cummins Inc. (Columbus, IN), for traditional warehouse space,” says Baugh. “Also, extensive use of line- sequenced major components has resulted in similar inventory reductions. All of this is resulting in less warehouse stocking and increased use of satellite staging areas for fast flow movement of components from dock to point of use.”
High-Tech Tools Information technology plays a significant role in the assembly process at Renton. For instance, conventional build paper has been computerized into a chassis image. The chassis image system is a user-friendly application with computer stations strategically located along the assembly line. Operators run a daily build query that provides them with specific parts for their specific area of assembly. Assemblers frequently access elec- Kenworth views itself not as a truck company that uses technology, but rather as a high-technology tronic engineering diagrams and bills of company that builds trucks. Photo courtesy Kenworth Truck Co. material. “By eliminating the need to 46 ASSEMBLY / November 2004 www.assemblymag.com 38_asb1104plantofyear3.qxd 10|14|04 11:51 Page 48
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sort through multiple pages of real-time environment. “Hav- build paper, the opportunity to ing accurate information faster, install the wrong part or miss a whether it is quality informa- required part is lessened,” says tion like mil thickness on a Baugh. “This online version pro- painted surface, or part deliv- vides more time for employees to ery, we make faster business concentrate on the quality of decisions every day,” says their work.” Stevens. In July, Kenworth unveiled another new shop floor software New Production Tools program, in conjunction with Kenworth engineers con- Microsoft Corp. (Redmond, stantly search for new ways to WA). This Web-based tool increase productivity and serves as an online encyclope- Since the Renton plant opened in 1993, it has built more than improve customer satisfac- dia of information on every 80,000 heavy-duty trucks. Photo courtesy Kenworth Truck Co. tion. “By implementing key truck assembly task with a click capital investments in produc- of a button. Employees can click on a using tablet PCs. The devices are more tion technology and computerized button and find out the specifics of commonly used in the health care and applications on the production floor, their job or a specific task. insurance industries, but they have we are better able to focus resources The Web-based tools work together numerous benefits on the plant floor. where they add the best value,” to enable production staff and They give users the ability to write explains Zitzelberger. management to monitor work-in- directly on a portable, handheld screen Over the past few years, an extensive process in the plant. They also allow with an electronic stylus. effort has been undertaken to record inspectors to capture information on the Tablet PCs allow Kenworth to cap- torque control throughout the Renton assembly line where they can resolve ture more accurate information in a plant, which uses hundreds of threaded problems prior to the completion of the fasteners to build trucks. Substantial manufacturing process. investments have been made in direct A series of “quality gates” are current tooling on critical fastening located throughout the Renton plant. applications at the plant. All tools have Mechanical quality is checked on the been networked with a program so that main line, just before the cab is attached run-down information can be accessed, to the chassis; at the cab trim exit; and torque values trended, and predictive at the end of the main assembly line. maintenance performed as required. Paint quality is checked on the main This application allows manufacturing paint line, just before the cab is released engineers to electronically monitor and to the trim line. report on all DC tools within the plant. “By creating a real-time production “The DC tools provide superior database with our systems, we are able torque control over traditional air- to prioritize efforts through trend powered assembly tools,” claims analysis and make faster quality Stevens. “The technology allows us to advancements,” claims Zitzelberger. control torque at Six Sigma levels or He says the software application has higher. This investment has also dramatically improved the way engi- allowed us to use different fastening neers interact and communicate with strategies to ensure not only that the operators on the plant floor. correct torque is applied to a given “Benefits include easy access and fastener, but also the correct clamp the ease of adding useful information, load, which ultimately is what is such as posting content, in a structured important.” manner,” adds Stevens. “There is a The electronic controls also enable greater willingness to share lessons error proofing. The tools automatically learned and training documentation by An assembler installs a wiring harness in the cab adjust themselves, based on specific a wider audience due to the user of a Kenworth truck. Many vehicles are equipped chassis configurations. friendliness of the software.” with state-of-the-art tools, such as navigation Kenworth has installed DC electric systems, satellite radio, collision avoidance On the plant floor, assemblers, qual- warning systems, night vision and stability tools throughout the Renton plant, most ity improvement technicians, material control braking systems, making assembly and notably in the motor department where coordinators and line managers are testing more complex. Photo by Austin Weber most of the drivetrain components are 48 ASSEMBLY / November 2004 www.assemblymag.com 38_asb1104plantofyear3.qxd 10|14|04 11:51 Page 50
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the way for increased throughput,” says Baugh.
People Power Even with state-of-the-art technology, Kenworth relies heavily on people to ensure the quality and value of its prod- ucts. “The employees of the Renton plant take great pride in the products they deliver to the market,” says Baugh. “Maintaining our leadership position in the industry drives us to continually decrease waste, as well as constantly evaluate ourselves to improve our in- plant processes. “Although much of our marketing, sales and design engineering efforts are done at a separate location, the employ- ees at the Renton plant are well inte- grated into all aspects of Kenworth’s Because of the large size and unique requirements of off-road trucks, the Renton plant builds them business,” adds Baugh. in a dedicated area of the factory. Photo courtesy Kenworth Truck Co. Six Sigma has been fully imple- installed. “The most expensive portion “RFID reduces the retrieval time of mented at the plant as both a problem- of a truck is the drivetrain,” notes parts being painted,” adds Baugh. “It solving methodology and a business Bechtold. “Technology is applied to has proven to be more reliable than strategy. The Six Sigma methodology is these assembly processes to ensure that the optical-based sensor system it applied to production processes, quali- these critical components are assembled replaced.” ty control, new product introductions accurately to the supplier-prescribed In addition, the Renton plant and transactional processes. torque specifications. recently installed robots in the base “Employees with demonstrated “Applying technology to ensure and clear coat booths, which are used problem-resolution abilities from a accuracy of our critical assembly to automatically paint cabs, hoods diversity of backgrounds are trained in processes has further enhanced our and sleepers. The technology has the theory and application of Six Sigma product quality,” adds Bechtold. “The improved the quality of the paint jobs methodology as either black belts or DC tools produce an extremely high and the cycle times. “This will pave green belts,” says Baugh. “They then and reliable CpK to eliminate the need to inspect for correct torque values. They have improved our control of clamp load on mechanically fastened joints.” The Renton plant has also been applying technology to streamline the flow of material to the assembly line. “The goal of our supply chain manage- ment effort is to continuously improve material availability for truck assembly through a pull system,” says Baugh. Earlier this year, the plant began testing the use of radio frequency identification (RFID) technology. “It will enable us to quickly receive and locate parts throughout the production line and produce cost savings through dunnage reduction,” explains Baugh. The technology is currently used for No matter what they haul, all truck operators are faced with the same challenges, such as rising fuel product tracking and power-and-free prices and driver retention. To address these issues, Kenworth engineers are constanly searching for conveyor management in the paint shop. new innovations that help customers gain life-cycle cost advantages. Photo courtesy Kenworth Truck Co. 50 ASSEMBLY / November 2004 www.assemblymag.com 38_asb1104plantofyear3.qxd 10|14|04 11:51 Page 52
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Each truck on the Renton assembly line is Every Kenworth vehicle is custom-engineered, from bumper to taillight, to meet customers' unique different than the next. Photo courtesy requirements. Photo courtesy Kenworth Truck Co. Kenworth Truck Co. lead cross-functional teams to resolve parts for easier access and reduced returnable rack into the cab for mounting. issues and continuously improve the walking distances. An air cleaner lift device uses an facility’s operations.” “The management team makes a electric-powered balancer to provide a Kaizen events are another continu- conscious effort to ensure the work- weightless feel to the parts when they ous improvement process for the facili- place is a place where our employees are being inserted onto the cab. ty. According to Baugh, these events, want to come to work,” adds Baugh. Suspended torque tools use air which focus on using a cross-section of “Safety, communication, quality and balancers to provide a weightless feel to employees, have eliminated non-value- increased productivity are the major the tools, which reduces assembler added activities and generated signifi- focus areas.” fatigue and repetitive stress injuries. cant savings by reducing inventory, Although the State of Washington “Our strategic long-term goals scrap and dunnage, as well as relocating has some of the country’s most focus on breakthrough performance in stringent ergonomic standards, the quality, safety and performance met- Renton plant has taken a proactive rics,” concludes Baugh. “We continue approach to addressing this challenge to move forward with an aggressive on the assembly line. In fact, last year, plan to increase the use of technology the facility received an Ergonomics in to make the assembler’s job easier, Action award from the Washington faster and safer. To maximize profits State Department of Labor and and improve productivity, the man- Industry for reducing hazards in agement team strategically submits material handling and production capital funding and operating budget operations. requests to focus project management Assemblers use a wide variety of on eliminating waste, improving plant fixtures, tools and material-handling efficiencies, reducing truck hours, devices to eliminate fatigue and improve improving quality and ensuring a safe the work environment. For instance: work environment.” A A tilt fixture allows operators to easily manipulate the entire cab for ergonomic installation of rooftop- mounted components, such as lights, horns and antennas. Find out more about Kenworth’s A seat lift device uses an air- The Renton plant has quality gates set up in Renton plant with a click! strategic locations, such as at the exit of the powered balancer to provide a weightless paint shop oven. Photo by Austin Weber feel when transferring seats from the www.assemblymag.com 52 ASSEMBLY / November 2004 www.assemblymag.com