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Presentation

Lean Success in a Low-Volume/High-Mix Manufacturing Environment

Applying lean in unexpected places

Presentation Code: VS1-03

Value Stream: VS1 - Fundamentals of Lean

Day & Time: Tuesday, Oct 16, 2012 - 1:30 PM

Length: 1 hour, 10 minutes

When we think of lean, we usually think of high-volume, standardized-product processes. In fact, some people say lean won't even work in a low-volume/high-mix environment. But that's not the case - and CMC is a shining example of how lean can work in a low-volume/high-mix company, even when it has a takt time of one per week. In fact, it's through using lean that the company received the Progressive Manufacturing Top 50 Award from Manufacturing Automation magazine in 2007. Lean had helped them to achieve record shipment, triple inventory turns, a 70% reduction in WIP, a 60% reduction in manufacturing cycle time, a 300% improvement in on-time deliveries, a 35% productivity improvement and a 40% cut in response time on service parts orders. And CMC did this by using tools such as 1) a pull system of production, 2) 5S, 3) SMED, 4) synchronous flow, 5) cellular manufacturing and 6) single piece flow. Success like this is something you will want to hear about because this company has lessons to share.

In this presentation:

  • Hear how to put lean to work in a low-volume/high-mix manufacturing environment.
  • Learn about fundamental concepts you need in order to build lean success.
  • Find out about management's role in assuring success.
  • Learn when and how to apply the key tools for achieving success.
  • Take home valuable information you can use at your business.

Card-Monroe Corp. (CMC)

Founded in 1981, CMC is located in Chattanooga (Hixson), Tennessee. The company produces custom machines for the carpet manufacturing industry and currently has over 1,900 state-of-the-art tufting machines in operation on six continents. The majority of its business relationships are longstanding and they pride themselves on the strength of those ties.

Jim Joyner

Jim Joyner is vice president of corporate excellence for Card-Monroe Corp. He has been an RAB lead auditor, an examiner for the Tennessee Center for Performance Excellence and a judge for the MA Manufacturer of the Year award. Jim is certified by the University of Tennessee's Lean Enterprise Institute and is a six-sigma black belt. He has authored several books and is a featured Journal of Concurrent Engineering contributor. Jim graduated from the University of Tennessee at Chattanooga and earned an MBA from the College of St. Thomas in St. Paul, Minnesota.

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