10 • Pre-Conference Workshops
day-long workshops provide you with key skills and knowledge for
adopting Toyota-style production. We highly recommend that conference
attendees who have not been trained in these topics participate
in the optional pre-conference workshops.
to Basics - Introduction to Lean Principles
Bob Anderson, former Plant Manager, General Motors’ Lansing Grand
session is a practical discussion on the principles of lean manufacturing,
suitable as an introduction for the newcomer and an excellent refresher
on the basics for the more experienced. The session will highlight
the “what” and “why” of the lean principles, preparing the participant
for both practical application and additional future in-depth study.
Using Value Stream Mapping to Drive Improvement
Michele McLaughlin, Principal, MMc Associates, LLC
David Pilmore, Vice President Operations & Sales, Adrian Steel
is a presentation for both new and experienced mappers. Participants
new to Value Stream Mapping will learn the basic icons as well as
see a case study example of how the tool has been practically applied
at a real plant. Using Adrian Steel Company, a manufacturer of service
van interiors for the commercial and fleet industry, participants
will see a progression of Value Stream Maps showing improvements
achieved over the last five years and their plans for future improvements.
Q&A with David Pilmore will include a discussion of accomplishments
achieved and mistakes made using the PDCA, scientific method.
Rick Harris (co-author of Creating Continuous Flow and Making Materials
that we are using the "Value Stream Mapping" and "Creating
Continuous Flow" tools to identify waste and develop efficient
manufacturing cells, we have the important task of effectively delivering
material to the cells so that the operators can meet their TAKT
time requirements. This workshop will cover in detail the four necessary
parts to a Lean Material Movement System: Plan For Every Part, Purchased
Parts Market, Pull Signals, and Delivery Routes. This workshop was
developed to train companies and organizations in the most efficient
way to move material throughout their manufacturing facilities.
11 • Opening Plenary Session
From Detroit to Japan and Back Again
begin with a plenary session that analyzes the origins of lean and
takes us inside one of the biggest transformations of all time:
assembly operations at the Ford River Rouge site. Jim Padilla, Jim
Womack, and John Shook will explore Ford’s development of the initial
flow principles, their transformation into mass production, how
Toyota improved and changed them back into lean and how they are
now returning to Detroit. Dennis Profitt and the Ford Rouge Team
will explain their journey, including a discussion of their objectives
President, North America and Executive Vice President Ford Motor
Company, will take us on a tour of lean at Ford, its early development,
how Ford got distracted by the immediate benefits of mass production,
and how Ford is finding its way back through the Ford Production
Jim Womack, President and Founder, LEI. Co-author of The Machine
that Changed the World, Lean Thinking, and Seeing the Whole: Mapping
the Extended Value Stream, will continue the journey through time
in ‘A Century of Lean Thinking’.
Shook, Toyota veteran, experienced guide to lean implementations,
and co-author of Learning to See, was the first American to become
a manager for Toyota in Japan. There, he worked with Toyota executives
and became a passionate student of the Toyota enterprise. John will
discuss, in detail, how Lean Principles are coming back home and
are helping companies achieve impressive results.
Dennis Profitt, Director, Manufacturing Operations VO & Site
Manager, Ford Rouge Center, will moderate a presentation on the
Ford Heritage project that is transforming the Rouge into a model
of lean and sustainable manufacturing.
Heritage Plant Tour
afternoon will be spent at the new Ford Heritage Truck Plant within
the River Rouge complex. Conference attendees will have the opportunity
to see, for themselves, lean principles and practices in operation
as Ford F150 trucks are built in this flexible operator- and environment-friendly
facility. This unique tour held just for this conference will be
led by lean experts who worked on the detailed design and launch
of the plant.
will be dedicated to workshops featuring hands-on training sessions
and case studies that teach lean principles and tools, and provide
Rother, co-author of Learning To See and Creating Continuous Flow
Jim Hines, professor of system dynamics in MIT’s Sloan School of
Brian Schlake, Greg Pothoff, and Phillip Aubert, lean practitioners
at Johnson Controls.
production, or Heijunka, is one of the first steps and most important
foundation stones in the Toyota Production System. It is a vital
but overlooked method for driving continuous improvement.
I: The Beer Game, Dr. Jim Hines. Track participants run a supply
chain for the liquid fruit of barley (with just a touch of the hops),
providing hands-on experience that illuminates dynamics in the value
II: Do You Know Your EPEI?, Mike Rother. Participants learn to use
“Every-Part-Every-Interval” calculations, a remarkably valuable
tool, in developing ever better value streams.
III: Gaining Understanding through Execution: Our Experiences with
Heijunka, Brian Schlake, Greg Pothoff and Phillip Aubert will describe
one of the most brilliant applications of Heijunka outside Toyota,
at the Johnson Controls interiors facility in Holland, Michigan.
for Developing and Improving Manufacturing Processes to Support
Eric Ethington, Lean Enterprise Manager
Erica Hobbs-Gutberlet, Manufacturing Support Team Manager, from
Delphi’s internal Lean College.
workshop designed to provide an understanding of the lean concepts
fundamental to the creation and improvement of flow in a manufacturing
system. Participants will be challenged to develop their skills
of observation and eye for Kaizen. Special focus will be given on
the role of the leader in this environment. As a test for understanding,
the group must take a current manufacturing system, identify the
Kaizen opportunity and effect an actual change. Get ready to roll-up
your sleeves and get to work!
Due to the nature of this session, space is limited. Admission
will be on a first-come, first-served basis.
of Shop Floor Management - The Toyota Approach
Keith Allman, Vice President Merrillat Industries
Bill Costantino, Consultant and former Toyota Manager
Keith Allman and Bill Costantino team up to share the details of
a recent transformation at Merillat’s Adrian assembly plant. Using
Toyota as a benchmark, they customized a shop floor management system
that has led to significant performance improvements. We will review
specific tools for workgroup involvement and day-to-day management
strategies for lasting cultural change in this detailed case study.
Deployment – Making Knowledge Flow
Pascal Dennis, author of Lean Production Simplified
Erik Hagar, both former Toyota employees.
Policy Deployment is the world’s most powerful planning and execution
system. It is also the brain and nervous system of Lean production.
Policy Deployment compels consistent use of the scientific method,
makes problems visible and drives countermeasure activity. It also
helps us answer critical questions such as: What are our critical
needs? How do we focus our resources? How do we involve and motivate
our team members? How do we sustain our activities? How do we learn
from our successes - and failures? Policy Deployment makes knowledge
flow at every level of the organization.
Chain Science: similarities and differences in applying lean
Steve Hoeft, Senior Analysit, Altarum
Lean principles apply well within the four walls of a factory, but
why are they so difficult to apply to multiple factories in a Supply
Chain? Have you really tried to apply lean principles to a Supply
Chain? This presentation establishes a framework for comparing and
contrasting the application of Lean principles and tools to both.
One example is Value Stream Mapping. This tool avoids the backsliding
and uncoordinated results from scatter-shot Kaizen “blitzes”. So,
why shouldn’t Value Stream Mapping applied to supply chains as “systems”
accomplish the same thing? Other examples parallel Quick Changeover,
Pull, Error Proofing, Information flows, Importance of joint, formal
Problem Solving, level production (yes, level), Six Sigma projects,
Takt Time and even better ways to achieve buy-in and reduce distrust.
the Enterprise: incorporating the office into value stream management
Beau Keyte, President, Branson Inc.
Waste on the shop floor is caused, in part, by production support
processes. Once companies begin to understand their production systems
from a lean perspective, it’s time to challenge and redesign the
office support processes from an “enterprise” perspective. This
workshop will relate value stream management to administrative areas
and get you started in identifying key problems and focusing the
direction of your lean efforts in the broader organization.
to Lean at General Motors: Lansing’s success story
Ken Knight, G.M. Plant Manager
Bob Anderson, former Plant Manager, General Motors’ Lansing Grand
Join the leaders who guided the development and realization of General
Motors’ Lansing Grand River (LGR) Assembly Plant for discussion
of the key enablers that are essential to realizing lean results.
The LGR project represents GM’s latest in thinking for lean manufacturing
technology and produces the very successful Cadillac CTS. This session
will offer first-hand observations of how the transition to lean
manufacturing is being achieved within General Motors today.
Toyota Way: The Culture behind the Toyota Production System
Jeffrey Liker, Professor, University of Michigan.
Lean manufacturing is sweeping the world as the next paradigm of
manufacturing effectiveness. The model is the Toyota Production
System. But what is the paradigm? Many companies are mistaking the
tools of Lean--kanban, cells, 5S--for the Toyota Production System.
Now referred to by Toyota as the “Thinking Production System,” lean
is about driving value to customers by continually improving your
process through total employee involvement. It is built on the principles
of the Toyota Way. The
Ultimate goal is a lean learning enterprise that delivers exceptional
value to customers. Dr. Liker will talk about the lean learning
enterprise drawing on his new book, The Toyota Way (McGraw Hill,
of Lean Product Development
James Morgan, Director, Lean Product Creation, Ford Motor Company
Jeri Ford, New Program Strategy Manager, Ford Motor Company.
Product development may be the single most important element in
the Lean Enterprise. It can be a tremendous early leverage point
for designing in enablers for lean manufacturing. In fact, it impacts
nearly every other functional group and can determine the future
of the entire organization. Therefore it is surprising that lean
product development systems have received relatively little attention
in the literature. In this session we examine the research and principles
that form the core of an only-recently-recognized PD system that
is to product development what TPS is to manufacturing and how this
system is being employed to change the way new products are being
You Can’t Flow - Pull
Greg Ruddy, President, Ruddy's Lean Systems, Inc.
This workshop walks you through a real-life example of setting up
a lot-by-lot visual replenishment system, the concept of knowing
what normal is, and some of the philosophy behind pull systems.
Greg has nearly ten years of experience implementing pull systems
at both automotive and non-automotive companies, and can help you
avoid stumbling blocks in your effort to introduce pull.
-Lean Principles at the Rouge Truck Plant: An In-Depth Look, Ford
Come and learn about Ford’s new flagship plant! A team from Ford’s
new truck plant in the Rouge complex will provide an in depth analysis
of what makes this plant an icon of 21st century manufacturing.
They will analyze both the lean principles and tools utilized in
the plant, as well as the sustainability issues addressed.
Closing Plenary Session
Can You Do Right Now?
of the conference on Thursday morning will pull together leading
practitioners and lean advisors to offer practical recommendations
for companies on the lean journey. The first half of this presentation
will be led by key expert practitioners from industry who will focus
on what you need to do next and why. They will assess the state
of lean as a movement in industry, provide their view on the major
issues and challenges facing companies in their lean journeys, and
state their analysis and suggestions regarding things to do now
and in the future. Dennis Profitt, Site Manager of Ford Rouge &
Russ Scaffede, former Vice President of Toyota’s powertrain operations
as a participant, will design the remaining half of the closing
plenary. Questions will be collected from attendees during registration
(see registration form), tallied, and the top ten will be given
to a panel of experts to present their thoughts. This panel will
include Walt Hancock, Professor Emeritus, University of Michigan,
Jeffrey Liker, David Logozzo, Manager, Manufacturing Systems and
Lean Enterprise Initiative, Delphi Automotive Systems, Dennis Profitt,
Russ Scaffede, John Shook, & Jim Womack.