Milestone celebrated by improving productivity, quality, delivery

WIKA Instrument Corporation recently celebrated its 300th Kaizen event which took on the task of improving productivity, quality and delivery, as well as updating standard work and developing data for routing purposes for the 1830 production cell

03/24/2011


WIKA Instrument Corporation (WIKA) recently celebrated its 300th Kaizen event. The Kaizen took on the task of improving productivity, quality and delivery, as well as updating standard work and developing data for routing purposes for the 1830 production cell. This cell produces WIKA’s 23X.30, 23X.50 and 23X.54 stainless steel 4” pressure gauges.

Kaizen’s are practices that focus on the continuous improvement of processes in manufacturing, engineering, business processes and management. Kaizen’s are based on making small changes on a consistent basis and continually improving productivity and eliminating waste.

Since WIKA conducted its first Kaizen in June 2001, the company reportedly averaged one event per week for the next nine years. By investing over 96,000 hours and 70 percent of WIKA’s workforce into Kaizen participation over time, WIKA has allegedly seen a 40% increase in productivity without an increase in labor. “Reaching 300 Kaizen events is an accomplishment that solidifies WIKA’s commitment to Lean manufacturing and principals,” said Director of Continuous Improvement and Quality, Rick Reed.

WIKA has solved problems ranging from making improvements to work areas and eliminating waste, such as converting pressure gauges from a manual line to an automated line—saving WIKA approximately $141,000—to business operations and how to conduct expedite procedures through our order entry system starting in order entry and finishing in shipping. In 2010, Kaizen events reportedly produced a cost savings of approximately $600,000 for WIKA.

In 2010, WIKA took the next steps in its lean journey by introducing Six Sigma and Green Belt training to its workforce. Six Sigma is the process of identifying and removing defects and errors. Green Belt certified employees are the experts in Six Sigma methods.

www.wika.com

WIKA Instrument Corporation

- Edited by Amanda McLeman, Plant Engineering, www.plantengineering.com



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
July/Aug
GAMS preview, 2018 Mid-Year Report, EAM and Safety
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
August 2018
Choosing an automation controller, Lean manufacturing
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
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 Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me