2003 Shingo Prize Winners

The Shingo Prize promotes awareness of lean manufacturing concepts and recognizes companies that achieve world-class manufacturing status. It is named for Dr. Shigeo Shingo a leading expert in improving manufacturing processes. The prize is presented to manufacturing sites that have achieved dramatic performance improvements.

04/08/2004


Sections:
ArvinMeritor, Gladstone Plant
Delphi CENTEC, Plant 98
Delphi Corp., Parral Plant
Delphi Corp., Plant 5100
Delphi Corp., Plant 58
Delphi Corp., Plants 5 & 6
Delphi Corp., Empresas CA-LE de Tlaxcalla Plant
Delphi Electronics & Safety, Kokomo Operations, Plants 7 & 9
Delphi Sistemas de Energia S.A. de C.V.
Maytag Jackson Dishwashing Products
Raytheon Missile Systems
TI Automotive - Cartersville

The Shingo Prize promotes awareness of lean manufacturing concepts and recognizes companies that achieve world-class manufacturing status. It is named for Dr. Shigeo Shingo a leading expert in improving manufacturing processes. The prize is presented to manufacturing sites that have achieved dramatic performance improvements.

Following is a listing of 2004 Shingo Prize winners with a few of their accomplishments.

ArvinMeritor, Gladstone Plant

This 403,000-sq ft operation in Columbus, IN, employs 700 people in 54 work units. Products are automotive exhaust components and systems. There are 71 employee involvement teams. MRO inventories have been reduced 73% since 1993. Ontime delivery has average 99.99% since 1999. Scrap has been reduced 43% in the past 3 yr. Training time averages 40 hr per employee annually.

Delphi CENTEC, Plant 98

The 470 employees at this Ramos Arizpe, Coahuila, Mexico, plant have compiled 1.7 yr without a lost workday case. Maintenance cost per ship hour has been reduced 42% from 2000 to 2003. Uptime has improved 35% from 1999 to 2003. Scrap has been reduced 74% over the past 3 yr. Plant makes a variety of components for automotive wiring harnesses.

Delphi Corp., Parral Plant

With 141,573 sq ft of manufacturing space and 2220 employees, this manufacturer of automotive electrical/electronic distribution systems has cut its maintenance cost per hour by 46% since 2000. Uptime is running at 88.6%. Ontime deliveries from the plant have been 100% since it started up in 1998. The plant is located in Hidalgo del Parral, Chihuahua, Mexico.

Delphi Corp., Plant 5100

This manufacturer of truck and SUV wiring harnesses in Nuevo Casas Grandes, Chihuahua, Mexico, has amassed more than 4 million manhours (18 mo) without a lost workday incident, while reducing PPM defects by more than 80%. First-time quality (FTQ) improved 38% last year, and eight Shainin projects resulted in more than $220,000 in cost avoidance.

Delphi Corp., Plant 58

Maintenance costs were reduced 16% in 2003 at this Meoqui, Chihuahua, Mexico, facility while overall productivity was improved by 23%. Total product cycle time (TPCT) has improved 50% compared to 2000. The 151,000-sq ft, 1800-employee plant produces more than 3 million automotive wiring harnesses in 96 part numbers.

Delphi Corp., Plants 5 & 6

The recordable injury rate was 0.128 incidents per 100 employees in 2003 as time without a lost workday incident stretched to 22 million manhours at this Delnosa, Reynosa, Mexico, plant. Energy consumption has been reduced by 40% in kilowatt-hours consumed as a percent of production volume, and floor space productivity has improved by 46%. Manufacturing cycle time has been cut from more than 30 hr to less than 15 hr. The facility has about 500,000 sq ft of manufacturing floorspace.

Delphi Corp., Empresas CA-LE de Tlaxcalla Plant

Proactive maintenance expanded from a 48% level to 86% at this Tetla, Tlaxcala, Mexico, manufacturer of automotive maintenance-free and hybrid batteries. Each of the plant's 575 employees receives 150 hr of training per year. Scrap dollars have been reduced 73% while first-time quality (FTQ) has improved 73%. Ontime shipping is at 100%.

Delphi Electronics & Safety, Kokomo Operations, Plants 7 & 9

The 1200 employees at these Kokomo, IN, plants improved productivity, measured in units produced per labor hour, between 31% and 123% for three major value streams. Ontime shipping is at 99.8%. The plant provides complex electronic assemblies for automobiles, including audio components, inflatable restraint systems, powertrain controllers, and climate controls.

Delphi Sistemas de Energia S.A. de C.V.

This plant marked up 100% ontime delivery for the past 3 yr while improving productivity by 33% over 2 yr, and reducing per-unit cost by 35% over 4 yr. More than 250 improvement suggestions were implemented last year. Training averages more than 100 hr per employee annually. Close to 550 people are employed in the 143,800-sq ft plant in Chihuahua, Chihuahua, Mexico.

Maytag Jackson Dishwashing Products

Maytag Jackson, Jackson, TN, produces more than 100 models of dishwashers under various brand names using an "any model/any hour" assembly cell system. Machine uptime is consistently above 99%. Scrap and rework has been reduced by 64%, and productivity has increased by 29%. More than 2000 Kaizen events and 53 Six Sigma projects were completed in 2003. Total productive maintenance is among the various disciplines used to foster continuous improvement.

Raytheon Missile Systems

This Tucson, AZ, producer of missiles and missile systems for the U.S. military has saved more than $223 million through waste elimination over the past 3 yr. In 2003, the plant recycled more than 7000 tons of solid waste and significantly reduced hazardous waste byproducts. Its first pass yield rates on highly technical products are approaching 95%.

TI Automotive - Cartersville

This Cartersville, GA, manufacturer of automotive brake and fuel bundles uses a 4-module approach called Common Sense Manufacturing. One module drives improvement in asset utilization by improving overall equipment effectiveness (OEE) using total productive maintenance (TPM). The 277 employees at the 114,000-sq ft plant produce more than 7.4 million units per year.





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
2016 Product of the Year; Diagnose bearing failures; Asset performance management; Testing dust collector performance measures
Safety for 18 years, warehouse maintenance tips, Ethernet and the IIoT, GAMS 2016 recap
2016 Engineering Leaders Under 40; Future vision: Where is manufacturing headed?; Electrical distribution, redefined
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
Safety at every angle, Big Data's impact on operations, bridging the skills gap
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Driving motor efficiency; Preventing arc flash in mission critical facilities; Integrating alternative power and existing electrical systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role of plant safety and offers advice on best practices.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me