Begin with the basics

MANUFACTURING

Just-in-time, total quality management and other such tools do not necessarily create strong manufacturing systems.

Alot of people in the automotive industry seem to think that having the right "tools" is the key to a successful manufacturing system By tools I mean systems and programs that are aimed at improving quality, eliminating waste and reducing cost - all while helping produce an even better product.

Many of these tools have become common throughout the industry. Kaizen program, for example, are continuous improvement efforts that are driven by the ideas of the people who know the operation best - the people working on the plant floor.

Kanban systems are aimed at eliminating waste by having the right product in the right place at the right time. Total productive maintenance (TPM) programs drive increased equipment productivity. And value stream mapping which some call process flow mapping, is aimed at better understanding how all of the pieces of a manufacturing system fit together and knowing where bottlenecks occur so problems can be attacked at the most critical points.

Standardized work, continuous flow and quick changeover are other important tools that can help improve manufacturing And of late, many companies are introducing the Six Sigma philosophy which establishes process capability to reduce variation and improve quality.

Evidence of these tools and others is in place at virtually every automotive facility throughout the world. Most OEMs have invested a great deal of time and money to implement many such systems and programs in the hopes they will improve their manufacturing operations.

Yet in my worldwide travels, I also have seen very mixed results from their implementation. Why?. Because at too many operations I see companies that are trying to plant the seeds of lean manti without first tilling the soil. Many programs are put in place, but there is no foundation of a broad, overall manufactuing structure in place to support successful implementation.

At some companies, these tools are implemented separately from plant to plant and operation to operation These disjointed efforts limit the effectiveness of these tools. From TPM to error-proofing, these tools can be very successful in improving manufacturing operations - but only as part of a cohesive production system.

There are two key components that must be in place long before any of these tools can be effectively implemented.

First, all manufacturing organizations must have a well-structured organization with clearly defined roles and responsibilities. And an important part of the organization's role is to develop a clear, well-thought-out policy deployment process that essentially sets the targets in areas such as quality, cost safety delivery and productivity.

Second, all of these goals must be understood by everyone in the organization - from workers on the plant floor to managers at company headquarters. And even more than understanding, workers must embrace these goals and be commit ted to improving their manufacturing operation.

Without such a foundation, these tools are destined to become just another "flavor of the month," and are doomed for failure.

A well-stred organization with clearly defined roles and responsibilities and a committed workforce are the foundations of a strong manufacturing system With such a structure in place, organizations have the capability to move forward in solving problems and improving And these comp nies can pick and choose in "pulling" the necessary tools and training that can best help them achieve their targets and improve their measures, instead of gushing" them on workers and into areas where they may not be necessary or effective.

Just-in-time, total quality management and other such tools do not necessarily create strong manufacturing systems But they can help a good manufacturer with an accepting culture and philosophy - and an effective manufacturing system - become even better.

[Author Affiliation]

RON HARBOUR is president of Harbour and Associates, manufacturing consultants in Troy, Mich www.harbourinc.com