Freudenberg and NOK Group Reaches Major Milestone
9 June 1999
Freudenberg-NOK President & CEO Shares Benefits of Being Lean at Shingo ConferenceCOLUMBUS, Ohio, June 9 -- In a presentation on "Creating and Sustaining a Lean Culture" at the Shingo Prize Conference and Awards Ceremony at the Hyatt Regency Center here, Freudenberg-NOK President and CEO Joseph C. Day announced that the Freudenberg and NOK Group Companies reached a major milestone last month as they conducted their 12,000th kaizen (continuous improvement) project. "No other automotive supplier company is even close to this record," Day said. "But more importantly, these projects have created a manufacturing environment in which Freudenberg-NOK's parts per million (PPM) rates have dropped from a range of 1,300 in 1992 to less than 50 in the first quarter of 1999 on a production rate of 2.0 billion components per year." Conducted as part of Freudenberg-NOK's company-wide lean systems GROWTTH(R) (Get Rid Of Waste Through Team Harmony) program, these kaizens have created significant improvements in productivity, product quality, delivery, waste reduction, customer satisfaction and global competitiveness for the company. Additionally, Freudenberg-NOK has conducted hundreds of poka-yoke ("mistake proofing") projects -- procedures to prevent defects in manufacturing -- which have yielded more robust products, higher reliability in vehicle systems and, ultimately, a cost of quality that has dropped more than 60 percent since 1992. As the company's cultural cornerstone, the GROWTTH principles result in best practice methods and enable Freudenberg-NOK to be more responsive to its global customers, by helping cut product development time, simplify production and standardize products, processes and materials that are interchangeable anywhere in the world. Day said the robustness of the Freudenberg and NOK Group's products are best demonstrated by warranty failure rates in Japan of .03/1000 to .07/1000. These rates have now been duplicated in North America and Europe for Japanese vehicles due to the interchangeability of products and standardized manufacturing methods practiced by the Freudenberg and NOK Group. North American vehicle manufacturers and tier-one systems suppliers can dramatically reduce their warranty costs as part of the total cost-down efforts, according to Day. In fact, on three recent projects for North American customers, Freudenberg-NOK reduced its customers' warranty costs by $6 million, $15 million and $45 million. On projects such as the engine- sealing packages scheduled for model year '99 and model year '01, the warranty targets are lower by as much as 50 to 80 percent. "Each of these examples are the direct result of the practice of our GROWTTH principles, which yield the lowest PPM rates, reliable and robust products, and product consistency -- further resulting in lower warranty costs and higher customer satisfaction indexes for the consumer," Day said. The 11th annual Shingo Prize Conference and Award Ceremony honors recipients of the Shingo Prize, which is administered by Utah State University in partnership with the National Association of Manufacturers. Freudenberg- NOK is a past recipient of this prestigious award. The Shingo Prize recognizes companies throughout the United States, Canada and Mexico that have demonstrated outstanding achievements in manufacturing processes leading to quality enhancement, productivity improvement and customer satisfaction. Plymouth, Mich.-based Freudenberg-NOK is part of the Freudenberg and NOK Group Companies, which have total annual sales of more than $6 billion. With global automotive sales of approximately $3.5 billion, the Freudenberg and NOK Group ranks among the world's top 25 independent automotive suppliers. Through a global network of facilities spanning 24 countries with some 23,000 automotive employees worldwide, the supplier group offers its automotive customers globally integrated products, including sealing packages for transmissions, engines, brakes, axles and steering, NVH (noise, vibration and harshness) components and packages, and all rubber, plastic and PTFE components for suspension, electrical and fuel systems. The Freudenberg and NOK Group also offers an extensive portfolio of precision-molded products for the aerospace, appliance, business machine, fluid power, marine, medical, off-highway equipment and recreational vehicle markets. For more information, visit the Freudenberg-NOK web site at http://www.freudenberg-nok.com.