North American Manufacturers Honored With Shingo Prize
2 May 2000
North American Manufacturers Honored With Shingo Prize LOGAN, Utah, May 1 The Shingo Prize for Excellence in
Manufacturing selected one Canadian, two Mexican and five U.S. plants to
receive the 12th annual awards. "The Shingo Prize is the only industrial
excellence award program that focuses on 'lean manufacturing' or the
elimination of waste as noted by Henry Ford in 1926 and implemented into the
Toyota Production System years ago," according to Shingo Prize executive
director Ross Robson. "With NAFTA, more companies in North America have had
to become globally competitive, and the Shingo Prize is helping achieve this
objective," said Robson.
The College of Business, Utah State University administers the Prize in
partnership with the National Association of Manufacturers.
The seven renowned corporations include Baxter, Cydsa, Delphi (2 plants),
Ford, Freudenberg-NOK, Lockheed Martin and Lucent.
Baxter Healthcare North Cove facility, Marion, SC, manufactures containers
of IV and peritoneal dialysis solution. The use of lean production has
reduced lead time by 84% and improved on-time delivery to more than
99 percent.
Cydsa Policyd La Presa plant, Tlanepantia, Mexico, manufactures polyvinyl
chloride resins for synthetic fibers, toys, surgical gloves, vinyl planking,
bottles and rigid film. Continuous improvement has achieved a first pass
yield of 98% and a 74% quality cost reduction over 5 years.
Delphi CMM, Matamoros, Mexico, produces instrument panels, steering
wheels, interior grab handles and air bag module covers. Using lean
manufacturing, CMM has achieved less than 200 returned parts per million while
achieving 100 percent on-time delivery. The plant recorded 7.7 million hours
without a lost work day case.
Delphi Steering Plant 6, Saginaw, MI, supplies steering columns to GM,
Chrysler and Toyota and component parts for world-wide facilities. Plant
6 improved first-time quality by 82%, the parts/person/day ratio by 43%, and
posted 2 million hours without a lost work day case.
Ford Windsor Engine Pant, Windsor, Canada, produces the 4.6L and 5.4L
Triton V-8 and 6.8L V-10 engines. Utilizing Ford Production System
principles, the Plant has achieved 100 percent on-time delivery with an
inventory reduction of $15 million in 1999. The plant has received the Wards
Auto World 10 Best Engines for each of the last four years.
Freudenberg-NOK, LaGrange, GA, produces O-rings for automotive, aerospace
and semiconductor companies. Using self-managed cells, one-piece-flow and
pull production, on-time delivery was improved from 60 to 99.3% while reducing
manufacturing lead time by more than 75% since 1995.
Lockheed Martin Aeronautics, Fort Worth, TX, designs, develops and
produces the F-16 and related systems. Implementing lean principles have
reduced cost per unit by 38%, lead time by 46%, inventory by 95% and
manufacturing time by 25% for the F-16 aircraft.
Lucent Technologies Product Realization Center (PRC), Mt. Olive, NJ,
integrates the design, development, manufacturing and business functions for
new products. Since 1996, PRC reduced product-development cycle time more
than 50%, cost of goods 68%, and assembly defects 80%, with 100% on-time
delivery.
