Event Reports Tour America 1991: Something Special in Wisconsin
Touring seven plants in four days.
Kevin O'Shea, Nancy Palmer, and Pat Hartman
Employee participation, along with innovative Bemis Manufacturing Company, with customers and suppliers. technology and production methods, high Sheboygan Falls: The company recently developed a ven lighted the recent AME Tour America 1991 vis Problem Solving Through Employee dor system including in-house stores. This sys its to seven manufacturing facilities in south Involvement tem allows unusual raw material aVailability eastern Wisconsin. "It was quite a week! Begin Acommitment to continuous improve and zero finished goods inventory. Suppliers ning on a Monday evening, 30 AME members ment through employee involvement (EI) is also participate in new product development gathered in Milwaukee, WI for a week of tour strong at this family-owned company. Cross teams. ing, networking, benchmarking, and shop talk functional teams identify, define, and solve Allen-Bradley, a Rockwell International - long days and nights of sharing and com problems using root cause analysis, PERT Company, Milwaukee: paring 'Something Special in Wisconsin,", said techniques, and statistical analysis. Team World-Class Computer-Integrated Bob Reynolds of Briggs & Stratton, president of results are published in book form and dis Manufacturing AME's Midwestern region. tributed throughout the company. Employees Allen-Bradley's outstanding CIM perfor Daily plant tours of one-two plants, dis are trained through Network 21, a peer-based cussions about pockets of excellence at the host multi-media program including custom video mance was reflected in its World Contactor companies, and a Saturday wrap-up session for tapes developed at a local community college. Automated Assembly Facility. Customers like sharing ideas about excellence to be applied in Bemis gave the college a $25,000 equipment the 24-hour shipment guarantee, with the participants' own operations were among the grant and agreed to purchase added tapes on a capacity of up to 1000 variations; in seven Tour America activities. Following is a sample continuing basis. years, they've never shipped late. of the ideas shared. Executive Vice President Peter Bemis was Acompany-wide quality program initiat among the hosts at this injection molding ed in 1985 saved the company more than $129 John Deere Horicon Works, Horicon: million in quality costs and reduced the cost of Excellence in setup Reduction facility called ADF (automated defect-free). The plant runs seven days a week, 24 hours a quality by at least 60 percent, while market setup reduction receives intense scrutiny share increased in major product areas. On a at this iawn and grounds care equipment pro day, without supervision. Major product lines include medical deVices, humidifiers, lawn fur cumulative basis, the quality program paid duction facility. QUick change tooling, stan back $13 for every dollar invested. Current dardization and simplification of tool beds and niture, toilet seats, and custom molded prod ucts. challenges: changes to meet ISO 9000 reqUire tool clamps, changeover equipment at each ments and the goal of "Total Quality for Cus machine, programmable controllers, and Marquette Electronics, Milwaukee: tomer Satisfaction." qUick-connect air lines brought to the front of Empowerment and Strong Supplier Links equipment - these efforts, and close supplier Employees produce medical diagnostic Harley-Davidson, Wauwatosa: ties, cut setup times. Other Deere techniques: equipment (ECG or electrocardiogram Kanban, Cell Manufacturing, Vendor multi-pin connectors and an air-driven tool machines) and patient monitoring equipment. Ties mover. EqUipment demonstrations: 500-ton This work force of 1500 has flex hours, a fit The story of Harley-Davidson's Engme mechanical press die cart, lOoo-ton hydraulic ness center, a company stock ownership plan, a and Transmission facility, once near extinction press die exchange systems, and a 175-ton day care center, profit sharing, and no dress and now a lean, mean operation, is well Cincinnati CNC press. code. Personal relationships are encouraged known. Three major programs contributed to 34 Target Event Reports its turnaround: Materials As Needed (MAN ing process to select their own coordinators Horicon Works, Bemis Manufacturing Compa Harley's own brand of]IT), Statistical Operator (rather than supervisors) who coach and ny, Marquette Electronics, Allen-Bradley, Control (every employee responsible for quali encourage leadership. Employees have a strong Harley-Davidson in Wauwatosa, Eaton Corpo ty), and EI. Tour-goors agreed that Harley is sense of their role in supplier/customer rela ration in Watertown, and Briggs & Stratton, one of the few manufacturers sustaining con tionships. Milwaukee. tinuous improvement over ten years' time. Bob Reynolds also recognized the contri Briggs & Stratton, Milwaukee: Asked, "How do you keep the momentum butions of tour director Ken McGuire of MEAC, 00 IfRight, 00 If Now Cellular going?" Harley representatives said Kanban, as well as Kevin O'Shea of Kevin O'Shea & Manufacturing Attitude cell manufacturing, and close vendor relation Associates, Matt Englert of Briggs & Stratton, Briggs & Stratton's (B&S) production of ships are essentials. Other contributors: consci Nancy Palmer of Palmer & Associates, and Pat four-cylinder engines for industrial and lawn entious material handling, effective use of tra Hartman d The Starting Point for event plan and garden markets traditionally emphasized ditional machining equipment and computer ning and management assistance. aided technology, SPC, a well-trained work ways to maximize machine output and indi force, cellular manufacturing, and a sense of vidual piecework. It led to inventory stockpiles Kevin O'Shea of Kev;n O'Shea & Associates in work force involvement and pride. and their associated wastes. That situation Brookfield, WI, amtributed to this arlick wiIh Nancy changed in 1991, when the Large Engine Divi Palmer ofPalmer & Associates, Milwaukee, WI, and Eaton Corporation, Watertown: sion launched its "War on Waste." Pat Hartman a/The Starting Point, Brookfteld, WI, Self-Managed Work Teams and Focused factories within the two million Employee Ownership sq.ft. facility now achieve level loading through Nineteen empowered work cells (ten to cellular manufacturing. Only nine months 15 members per cell) manage manufacturing into a four-year plan, B&S converted 20 of the at this facility, where digital, mechanical, and planned 42 cells into one piece flow manufac electronic counters are produced. The concept © 1992MJE turing cells. Significant benefits include inven of spokes in a wheel works well: In the environ For information on reprinl.'i, contact: tory cutbacks, personnel reduction (direct and &sociation for Manufacturin~ Excellence ment spoke, for example, one employee per cell 380 West Palatine Road indirect), cost of quality, inventories, space is responsible for safety, housekeeping, haz wrn.lin& lL 60090 reduction, and setup reduction and elimina 7081520-3282 ardous materials management and communi tion. B&S stressed doing the right thing (cellu cation, employee chemical exposure, recycling @ lar manufacturing/one-piece flow) right. and waste management. Other spokes: E!, quality, cost, and manufacturing. Shared LtnImIIl/l Employees help to select equipment Tour America 1991 participants benefit (such as surface mount), building a sense of ted from the candid experience sharing of the ownership. Teams participate in the interview- host companies. Special thanks to John Deere
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