40 Best Practice Tours

Adhesives Research is a 50-year-old company and manufactures high-performance, custom pressure-sensitive adhesives, tapes, coatings, specialty films and laminates for the pharmaceutical, medical, industrial, electronics and web converting markets. Adhesives Research has 360 employees at its Glen Rock, PA, facilities and has been on its Lean journey for over three years. During this time, it has driven excellence through its people and has demonstrated strong use of the visual factory with its 5S Plus Safety Program, Pull Systems, SMED and use of Kaizen to drive Continuous Improvement. This tour provides an ideal opportunity to see a company putting excellence to work.

Dixon Valve & Coupling was founded in 1916 and is now a leading innovator in the hose and coupling industry. Located in historic Chestertown, on Maryland’s scenic Eastern Shore, for the past five years Dixon has been applying Lean concepts in its high mixed-model production environment. Pull systems have been implemented throughout production and have enabled key suppliers to ship orders to customers within 24 hours. This is particularly impressive for a company that can produce over 5,400 unique parts during manufacturing. Twelve machining cells have been implemented to-date and these required significant changes in layout. Each cell has established standard work instructions, 'plan versus actual' boards and other elements of Visual Management. Dixon also has an operator-assisted maintenance program that has improved equipment reliability. Besides Dixon’s operations, this tour also includes Dixon Valve & Coupling’s distribution center. The tour provides an excellent opportunity to view Dixon’s evolving story.  Member of the Maryland World Class Consortia (MWCC)

Something's brewing at Eight O'Clock Coffee — and it is Lean transformation. Even though Eight O'Clock Coffee has been quite successful and is the third largest seller of whole bean coffee in the U.S, in 2009, the company decided to embark on a Lean path. But this wasn’t going to be easy for a 150-year-old company in a 40-year-old facility, with long-term service union employees and a FDA regulated environment. That means taking a tour of this work-in-progress Lean implementation is an ideal opportunity to see 'before and after' conditions. By the time the AME Conference begins, Eight O'Clock Coffee will have already implemented four lines out of a total of 10 — quite an achievement in just one year. Each line will incorporate 5S, TPM, Visual Management and other Lean concepts. Equally important is that the foundation for cultural change is being created. This tour will give attendees the chance to learn from Eight O'Clock Coffee's approach in the critical first year and see what they can apply at their places of business. Member of the Maryland World Class Consortia (MWCC)

GE Healthcare is changing healthcare delivery in more than 100 countries by using its vision for an “early health” model focusing on early diagnosis, intervention and prevention. Take the tour and see GE Healthcare technology in action. See how modern flexible lines constantly flex into new configurations. See how visual metrics are used on a daily basis to monitor and improve production. See how team members rotate periodically into Kaizen programs that are used in the office. See how customer-focused customization of products is routinely incorporated into every unit as required. And see how workplace assembly stations are tailored to eliminate ergonomic and Lean Waste. As the world moves toward the “digital hospital,” GE technology for patient monitoring, imaging and information delivery is driving process change versus process driving technology. GE’s approach is to have the right piece of equipment available in the right place and in the right condition to meet patient care demands. Take this tour and see how GE is implementing change and how you can learn from GE Healthcare’s experience.

In a little over a decade, Germane Systems, a woman-owned business, has grown into a proven technology innovator, developing Custom-Off-The-Shelf (COTS) rugged data storage solutions for aircraft, ships, vehicles and UAV systems. On this tour, you will see some of the processes that have helped Germane become so successful. You will see how Germane Systems has converted its production areas to a series of cells where visual workplace designs, standardized on-line work instructions and a new facility layout have reduced the company’s defects by 80% and improved its lead time from five days to just five hours. You will hear how the development of new partnerships with Germane’s custom component suppliers is dramatically improving the flow of parts. You will see how the entire process is being tuned to not only increase flow but balance tasks throughout the kitting, assembly, quality control, burn-in and final inspection areas. You will learn firsthand how deploying daily team meetings and visual metric boards has helped increase production by over 50%. You will see how improvements to Germane’s repair depot program have exceeded customer expectations. Tour a company that has wrung the best of Lean into a facility filled with low-cost improvements. Germane Systems is a tour site you don’t want to miss.

GM Powertrain means “GM quality under the hood.” For 2010, GM's global line-up of advanced power trains is dedicated to driving consumers further on a gallon of fuel. For 2010 model year, many of GM’s power trains are equipped with features such as Direct Injection, Variable Valve Timing and Flex Fuel applications that allow for an overall, better driving experience. Take this tour and see some of what goes into world-class production. Visit GM Powertrain’s impressive 100 percent landfill-free facility that won the 2008 Green Manufacturing Award from the state of Maryland. Learn how Lean techniques of line balance, TPM, Visual Systems, andons and musical alarms are making a difference. Hear how management and union workers have fostered an open work culture with a "living agreement," rather than the traditional contract. Take this tour and bring new ideas back to your place of business.

Established as an assembly facility in 1973, Harley-Davidson Vehicle Operations in York, PA, is the largest Harley-Davidson manufacturing facility. The York facility covers more than 230 acres and has over 1.5 million square feet under one roof. Harley-Davidson has been recognized as a world class manufacturer since their turnaround in the 1980s and much of the company’s success was built around its implementation of Lean. On this tour, you will see the use of flow technologies and visual management techniques such as Kanban replenishment in the manufacture of the Touring and Softail® models, as well as for limited custom-made productions. You will be able to explore exhibits that detail the plant's history and guide you through the manufacturing and assembly processes. You will also have a chance to sit on current production motorcycles and get a behind-the-scenes look at the people, processes and products of York Vehicle Operations. You will be guided through various manufacturing and assembly areas, watch as parts are manufactured, see freshly painted and chrome plated parts, and at the end of the line, see where every motorcycle is roll-tested, prior to crating and shipping. If you have ever wanted to know what goes into manufacturing these magnificent machines, you won’t want to miss this tour.

Lehigh Phoenix services the U.S. publishing industry as the primary provider of cover components, overhead transparencies and juvenile book production. But Lehigh Phoenix is making changes. The company is going green and staying green throughout by continuing to forge ahead with its sustainable efforts in the workplace. See how Lehigh Phoenix has substantially cut down on the use of paper products within the office environment and has teamed up with local waste companies to make sure they are recycling as much as possible. Lehigh Phoenix also continues to find more environmentally friendly ways of carrying out production, from using FSC and SFI® certified paper to using inks derived from vegetable oil and rosin-based resins. Tours of the facility will consist of a walk-through of the entire component printing process, from prepress production through the scheduling, printing, quality assurance and shipping phases of production. Participants will see a highly efficient and environmentally friendly printing facility focused on producing high-quality book components. It will give you ideas you can use for your business.

Leonhardt Manufacturing is a Just-In-Time manufacturer of tubular products for the motorcycle industry and is a key supplier to Harley-Davidson and Grove Worldwide. Leonhardt Manufacturing was founded in 1970 as a one-man tool and die shop and has grown to approximately 90 people working in a modern 89,000 square foot facility. The company has skilled people and state-of-the-art equipment and serves some of the biggest and best OEM's in the motorcycle, recreational vehicle, construction and home and garden industries. During this tour, you will see how an employee-owned company has created a culture of Waste elimination by employing shop floor Lean manufacturing techniques, such as Value Stream Mapping, cellular manufacturing, Kanban, Poka-Yoke, SMED, employee involvement and visual management.

Lion Brothers has provided the finest in embroidered products to the world's most recognized organizations, corporations and brands for more than a hundred years. Today, the company serves more than 1,600 global brands and their fabricators and trading partners. Lion is continually creating and leveraging new forms of technology that provide innovative solutions to ensure their customers a quality product at an economical cost. During this tour, you will see quick changeover equipment improvements; workplace organization, specialization and flexibility with short lead-time orders; and point of use inventory. You will also learn how Lion Brothers achieves extraordinary success increasing its sales through integrating cutting edge fashion trends into its production capabilities and then helps its customers integrate these features into their garment product lines. Participants are sure to benefit from what they learn during this tour. Member of the Maryland World Class Consortia (MWCC)

Marlin Wire buys steel wire coils made from recycled steel from old cars, refrigerators and washing machines. Marlin takes these recycled steel coils and converts them into precisely engineered wire products for industrial users like GE, Honeywell, Boeing, Toyota, Siemens, Roche, Novartis, Baxter and Pfizer. During this tour, you will hear how Marlin helps promote manufacturing sustainability within its own factory by recycling all scrap steel and turning its scrap from a nuisance into profit. Besides being good for the company’s profits, this also reduces Marlin Steel’s environmental footprint. During this tour you, will also see how quick-changeover teams have reduced setup times and batch sizes; how RM has dropped through supply chain improvements; how WIP was dramatically reduced through cells with single-piece flow; how FG was slashed by reducing lead times; how shared weekly performance bonuses helped beat production targets; and how cross-training matrix is used to boost skills, cover weekly schedules and broaden team member work experience. There is a lot to be learned from attending this tour. Member of the Maryland World Class Consortia (MWCC)

With more than a century of combined experience, MarquipWardUnited is a trusted leader in the corrugated paperboard and folding carton industries. The company blends knowledge with creativity to develop cutting-edge machinery and controls, and its revolutionary designs have enabled corrugators to double their speeds, reduce Waste and improve quality. MarquipWardUnited’s landmark achievements have proven commercial merit, achieving greater profitability for its customers. Over the last five years, MarquipWardUnited has increased its operating income almost four-fold and doubled inventory turns even during these challenging times. Come see how MarquipWardUnited uses Lean tools in a high mix/low volume engineered-to-order environment that includes the use of Yamazumi boards to manage complex assemblies, the use of e-Kanbans to procure parts and the use of Visual Systems to control material flow. Member of the Maryland World Class Consortia (MWCC)

McClarin Plastics is a recognized leader in the custom design and manufacture of thermoformed plastic and fiberglass reinforced plastic. For over 50 years, McClarin Plastics has been helping companies of all sizes find creative solutions using reinforced plastic. Since 2000, McClarin Plastics has adopted Lean methodology and over that time has continually realized green benefits in the form of space allocation, Waste reduction, energy conservation and increased cash flow. During this tour you will see McClarin Plastics’ Lean Continuous Flow Work Cell concept, where the complete component production occurs. This has freed and reallocated 30,000 square feet of warehouse space and reduced the need to build a new facility, thereby conserving land and resources. During this tour, you will also learn how McClarin Plastics has leveled production activity to customer demand and see how this alteration has in turn lowered spikes in energy demand. In addition, you will see how the company manages machinery starts and stops around non-energy spike times. There is much to be learned from how McClarin Plastics is applying Lean to its business.

Northrop Grumman Electronic Systems is headquartered in Baltimore, MD, and is a world leader in the design, development and manufacture of advanced electronics for military, civil and commercial use. The sector provides a variety of defense electronics and systems, airspace management systems, navigation systems, precision weapons, communications systems, marine systems, space systems, government systems and logistics services. During this tour, you will have the opportunity to see the manufacturing processes for Advanced Electronically Scanned Array (AESA) radar systems, the rapid prototyping facility, some examples of Northrop Grumman hardware and some of the improvement efforts that have been implemented. See how Northrop Grumman puts efficient tools to work to make it a world leader. Member of the Maryland World Class Consortia (MWCC)

Phillips Seafood, Inc., started in the seafood business along Maryland’s Chesapeake Bay in 1914. Today, the company sells its crab meat to their own restaurant guests, as well as to consumers in grocery stores and to the chefs of other restaurants. Owning and operating plants as well as restaurants has placed Phillips in a unique niche in the foodservice world, and Phillips Seafood now manufactures crab cakes for sale around the world. Phillips is five years into its Lean implementation in this food-grade environment. During this tour, you will see the development of a strong 5S program with excellent use of Visual Management tools, as well as employee communication processes that help create the right mix of Excellence Inside to assure a high level of customer satisfaction. Member of the Maryland World Class Consortia (MWCC)

Located in Newark, DE. Siemens Healthcare Diagnostics Wholesale Hospital Equipment and Supplies is the subsidiary of Siemens Healthcare. It offers a comprehensive array of diagnostic products that provide highly effective ways to assist in the diagnosis, monitoring and management of disease. Their Continuous Improvement journey began in 2001 and tour participants will see examples of 5S, Visual Workplace, Total Productive Maintenance, 3P Lean Design, and application of the A3 process. Siemens Healthcare Diagnostics is one of the largest medical diagnostics companies in the world. It offers a comprehensive array of diagnostic products that provide highly effective ways to assist in the diagnosis, monitoring and management of disease. Their products and services offer a balance of science, technology and practicality across the healthcare continuum to assist healthcare professionals with the vital information they need to deliver better, more personalized healthcare to patients around the globe.

Volvo Powertrain, the strategic Powertrain center for Volvo Group, is responsible for the development and production of heavy-duty engines, transmissions and development of axles within the Volvo Group. Volvo Powertrain is One Team of many sites around the world and proud to be truly global. The facility in Hagerstown, Maryland is the headquarters for Volvo Powertrain North America (VPT NA), with approximately 1,100 team members in a cross-functional structure that brings together professionals from Manufacturing, Product Development, Purchasing, Quality & Customer Satisfaction, Project Management, Finance, Key Accounts, and Human Resources & Communications.

The Volvo Group brands that currently offer the competitive products produced at VPT NA are Mack Trucks, Volvo Trucks North America, Prevost, and Volvo Bus. Engine development is conducted in a world class 70,000 square foot laboratory, in which the Selective Catalytic Reduction technology was developed to meet EPA 2010 requirements. VPT NA was the first to be certified by both the Environmental Protection Agency and the California Air Resource Board. In addition to being cleaner, the 2010 engines offer industry-leading fuel economy, performance, and durability. The Hagerstown facility also features state of the art manufacturing and assembly operations. With The Volvo Way as its foundation, Volvo Production System (VPS) offers principles and practices including employee involvement, teamwork, process stability, built-in quality, just in time, and continuous improvement all aimed at eliminating waste internally and creating value for their customers. Areas referred to as Power Bases are used by VPT NA teams to gather for problem solving, performance tracking, and information sharing. Ultimately, the goal of VPS is to attain zero defects and 100% performance. VPT NA works under the principles of The Volvo Way and is committed to quality, safety and environmental care.

Founded in 1854, W.R. Grace & Co. (Grace) is a specialty chemical and materials company, with offices in more than 40 countries around the world. Attendees will visit The Grace Davison Technical Center. The center houses 13 labs, 40 offices, pilot plant production and warehousing activities, and develops processes and designs that enable new and next generation products to move to full scale production. On this tour, you will not only see how Grace has incorporated 5S and Visual Systems, you will also see how cross-functional teams build an outstanding environmental and safety record. This great achievement has culminated in the recognition by OSHA of Grace as a VPP Voluntary Protection Program, "Star" level company. Only one percent of all work sites in the US have achieved this distinction, and Grace is the first R&D facility to have been recognized in Maryland.

Wright Manufacturing, Inc. is a private manufacturer of professional grade lawn mowers for the landscape industry. Established in 1981, Wright Manufacturing saw several changes before it focused on developing a new type of riding lawnmower that allows the operator to stand up while mowing. In 1997, the first Wright Stander® rolled off the assembly line, and it has since set a precedent for a revolutionary new type of lawn mowing. In 2000, Wright introduced the Sentar®, a mower on which the operator has the choice to stand or sit! See how Wright has used Lean to win a market position in this competitive industry and continues to grow, even during the recent economic downturn. Learn how the company has applied 5S, Visual Controls and Heijunka to manage mix-model process flow. See how Wright Manufacturing has designed a supplier milk run to reduce transportation expense and inventory levels, and see how Wright has implemented kit carts to achieve one-piece-flow. Excellence Inside you have to see to believe. Member of the Maryland World Class Consortia (MWCC)