quality first – manufacturing execution system (mes)

26
LMS Manufacturing Execution System (MES) controls all assembly processes and ensures process control, complete traceability, quality gates and record retention. ality First – ality First – Manufacturing Execution System (MES) Manufacturing Execution System (MES)

Upload: vijaybijaj

Post on 01-Nov-2014

1.698 views

Category:

Education


2 download

DESCRIPTION

 

TRANSCRIPT

Page 1: Quality First – Manufacturing Execution System (MES)

LMS

Manufacturing Execution System (MES) controls all assembly processes and ensures process control, complete traceability, quality gates and record retention.

Quality First – Quality First – Manufacturing Execution System (MES)Manufacturing Execution System (MES)

Page 2: Quality First – Manufacturing Execution System (MES)

LMS

Plant Layout – Key ElementsPlant Layout – Key Elements

Ho

use

keep

ing

Qu

alit

y F

irst

Pla

nt

Lay

ou

t

Lear People

Product Design

Value Stream Mapping

ANDON Lean Layouts One Piece Flow Load Leveling / Line

Balancing (Heijunka)

Page 3: Quality First – Manufacturing Execution System (MES)

LMS

• A cornerstone of LMS. VSM was used to understand current flow, identify waste and execute principles to eliminate waste and arrive at the optimum future state.

Plant Layout – Value Stream MappingPlant Layout – Value Stream Mapping

Page 4: Quality First – Manufacturing Execution System (MES)

LMS

Plant Layouts – Andon SystemsPlant Layouts – Andon Systems

Stopped module

Materials

Maintenance

Production

Quality

Module Running

Andon communication systems make abnormal conditions immediately visible and apparent. Response systems are developed and adhered to in order to assure quick response and resolution

Page 5: Quality First – Manufacturing Execution System (MES)

LMS

Plant Layout – 1Pc Flow / Manage by Takt TimePlant Layout – 1Pc Flow / Manage by Takt Time

Decreasing line Takt time to coincide with customer’s Takt time. Reduce waste by building what is needed when it is needed.

Page 6: Quality First – Manufacturing Execution System (MES)

LMS

Plant Layout – Plant Layout – Level Loading / Line Balancing (HeijunkaLevel Loading / Line Balancing (Heijunka))

Heijunka allows the set up of robust flexible operations that optimize labor using strategic buffering and level loaded schedules to balance the work load.

Plant 2 Front Line - AFTER

0.00

10.00

20.00

30.00

40.00

50.00

60.00

10 20 30 40 50 70 80 90B 100 110 130 140 150 160 170 180 190 200 220 230 240 270 290 300 310 350 380 390 410 420 430 440 450 460 480 500 520 530 540 560 570

Stations

Tim

e [se

c.]

Weighted Average [Sec.] @ 65 JPH

TAKT TIME [TT] = 55.4s (65JPH)

CUSTOMER TAKT TIME [TT] = 57.1s (63JPH)

Page 7: Quality First – Manufacturing Execution System (MES)

LMS

Material Flow – Key ElementsMaterial Flow – Key ElementsH

ou

seke

epin

g

Qu

alit

y F

irst

Mat

eria

l Flo

w

Pla

nt

Lay

ou

t

Lear People

Product Design

Lean Containers & Packaging

Plan For Every Part (PFEP) / Plan For Every Station (PFES)

Central Material Storage Pull Systems (Kanban)

Page 8: Quality First – Manufacturing Execution System (MES)

LMS

• Another cornerstone of LMS. Right-sized containers is the key enabler of Lean Material Flow and effects the entire value stream. It ensures proper workstation design and layouts which optimizes value added labor, freight and protects product

Material Flow – Lean Containers & PackagingMaterial Flow – Lean Containers & Packaging

Understand TheTRUE COSTS

Of Incorrect Packaging

Page 9: Quality First – Manufacturing Execution System (MES)

LMS

ValueStream

Line SidePresentation

Ergonomics

Health & Safety

Indirect

Labor

Tran

spor

tatio

nA

nd S

hipp

ing

Lost

Cyc

les

Material

Flow

LaborEfficiency

Material

Storage

We Must Understand TheTRUE COSTS

Of Incorrect Packaging

Packaging Effects the Total Value StreamPackaging Effects the Total Value Stream

Material Flow – Lean Containers & PackagingMaterial Flow – Lean Containers & Packaging

Page 10: Quality First – Manufacturing Execution System (MES)

LMS

Tool and process used to determine flow rates, storage and delivery systems and line side presentation requirements. Designing stations from operator out to ensure operator success

Material Flow – Material Flow – Plan For Every Part / Station (PFEP / S)Plan For Every Part / Station (PFEP / S)

L W H

1 Latch ASM - Floor, O/B, 2RS, 60% LH, 920 L0033097AF,01 BAE 24 Returnable 12 15 10 2400 480 20 2 60 3 4 120 5 24 720 30 48 11 Latch ASM - Floor, I/B, 2RS, 60% LH, 920 L0033099AF,01 BAE 15 Returnable 12 15 10 0 0 2 0 0 4 0 2 24 0 0 48 01 Latch ASM - Floor, O/B, 2RS, 40% RH, 920 L0033100AF,01 BAE 24 Returnable 12 15 10 0 0 2 0 0 4 0 2 24 0 0 48 02 Cable ASM - Latch Synch, 2RS, 40% RH L0033114AD,01 Capro 150 Returnable 32 15 8 0 0 2 0 0 4 0 2 24 0 0 18 02 Cable ASM - Latch Synch, 2RS, 60% LH L0033115AD,01 Capro 135 Returnable 48 15 8 0 0 2 0 0 4 0 2 24 0 0 18 02 Cable ASM - Synch 40% I/B Master L0064674AD,01 Capro 145 Returnable 48 15 8 0 0 2 0 0 4 0 2 24 0 0 18 02 60% I/B MASTER SYNCH CABL L0064675AE,01 Capro 135 Returnable 48 15 7.5 0 02 Cable ASM - Floor Latch Release O/B 40%/60% L0064677AC01 Capro 290 Returnable 32 15 8 0 0 2 0 0 4 0 2 24 0 0 18 02 Cable ASM - Floor Latch Release I/B 60% L0064682AC,01 Capro 290 Returnable 32 15 8 0 0 2 0 0 4 0 2 24 0 0 18 0

Part Delivery Inventory control - SupermarketInventory Control - Line Side

Station #

PDM #Color Code

Supplier/Container Usage

Container SizeAvg Wkly

Usage (830)

Avg Daily

Usage (830/5)

Cntnrs per day

Part Information

Super Market (Y/N)

Min. Inv.

Hours on

hold

Station side inventory

SupplierStd

PackStd.

Cntnr

Cntnr Retrn

or Expnd

Row Part Description

Max Inv.

Hours on

holdMin Inv.Min

ContnrMax Inv.

Max Contr

Bulk / Supermarket

Storage

Bulk Storage for Supermarke

t

Station side inventory

Max Inventory Hours OH

~ Include Safety Stock

Max Inv.

Max Cntnr

Cntnr per

pallet# of

Spots

Page 11: Quality First – Manufacturing Execution System (MES)

LMS

Controls Inventory. Inventory costs and abnormal conditions are made visible and immediately dealt with.

Material Flow – Central Material StorageMaterial Flow – Central Material Storage

Page 12: Quality First – Manufacturing Execution System (MES)

LMS

Material Flow – Pull Systems (Kanban)Material Flow – Pull Systems (Kanban)

Pull systems are employed to regulate production flow. Tuggers are used to deliver sequenced parts. This levels production, materials flow, operator flow and controls inventory

Page 13: Quality First – Manufacturing Execution System (MES)

LMS

Advancing RelentlesslyAdvancing Relentlessly

Page 14: Quality First – Manufacturing Execution System (MES)

LMS

Not an event – a way of life Total culture change – workforce engagement is

criticalPeople are resistant to changeLinking Lean with headcount reduction (Lean is Mean)Comfort level with excess inventory – hidden waste

Has to be supported and embraced by all levels of management (Top Down Driven)

Transformation must be systematic & disciplined

What have we learned?

Page 15: Quality First – Manufacturing Execution System (MES)

LMS

Create a critical mass of knowledgeTraining, training and more trainingMessage and training must be consistentFollow up and redirect when necessaryReplicate learning's

Focus on improving operations first 2 key elements:

Value Stream Mapping – learning to seeMaterial flow – driven by packaging

Acknowledge success and celebrate.

What have we learned?

Page 16: Quality First – Manufacturing Execution System (MES)

LMS

The Trap! Connecting The Dots• Pull Systems• Window Receiving• Window Shipping• Point Of Use Delivery• Milk Runs• Kitting & Sequencing• Dolly Exchange• Electronic Kanban• Kanban Cards• Standard Delivery Routes• Buffering Strategy• Small Lot Production• Small Lot Containers• Standardized Work• Leveled Mix• Five ‘S’• Audio & Visual Controls• Andon System• Error Proofing• Fixed Position Stops• Decoupling• Self Direct Work Groups• TPM• Quick Changeover

Event

Project

Blitz

Blitz

Project

Pockets of SuccessMarginal Progress

Short Term Approach

TotallyIntegrated

SystemApproach

What have we learned?

Page 17: Quality First – Manufacturing Execution System (MES)

LMS

Dir

ect

ExecutiveSteering

Committee

Provide Strategic Direction Provide Resource Make Decisions Meet Regularly Guide Deployment

Pla

n

HeadquartersLean Support

Team

Provide Tactical Direction Coordinate Planning Develop Training Material Coordinate Training Develop Operating Standards Provide Lean Expertise Support Implementation Assess Progress

Imp

lem

en

t

Plant LeanFacilitators

Develop & Integrate Plans Execute Plans Conduct Training Assist Implementation Lean Resident Resource Conduct Assessment Process

• Established structure to drive implementation and a common approach.• Drives accountability by assigning responsibility.

LMS Deployment StructureLMS Deployment Structure

Page 18: Quality First – Manufacturing Execution System (MES)

LMS

• Lean Facilitator Training– 3 weeks training

• 1 week/month• Application of elements learned in week one reviewed in week 2 (week 2 in week 3)

– Candidates from all Lear facilities– Mentored, monitored and reviews with Lean Master– 30 elements applied to Project Area– Certification following completed Project Area

• In-Plant Training– Kaizen events used to teach and apply– Events held by Plant Lean Facilitator and or Lean Master– Training records maintained by plants

Lean FacilitatorsLean Facilitators

Provides consistency throughout Corporationwhile ensuring correct usage of tools andtechniques for optimal resolution

Page 19: Quality First – Manufacturing Execution System (MES)

LMS

Week 1 Training

7 Wastes

Value Stream Mapping

5S

Ergonomics

PFEP/ PFES

Week 2 Training

Packaging

Pull Systems

Load Leveling

Andon

Week 3 Training

TPM

SMED

Poka Yoke

PDCA

Week 1 Week 5 Week 9Week 7 Certification

Week 1 Deliverables7 Wastes Examples

Initial Lean AssessmentBefore Pictures

5 S Workshop & MatrixErgo Kaizen & Matrix

PFEP / PFESCurrent State Map (begin FSM)

Current LayoutUpdate Lean Assessment

Week 2 DeliverablesCurrent State Map

Updated Future State MapApply PFEPApply PFES

Pull System w/ Pictures% Loading Chart & Matrix

Top 3 Packaging Business CasesUpdated Layout

Update Lean Assessment

Certification DeliverablesUpdated Layout

Optimized Lean Layout (Flow)Apply TPM

Apply SMEDPDCA Workshop & Matrix

Completed PlanLean Assessment

Plan For Each PlantClose all matrix items

Certification Presentation

Week 3

Lean Facilitator TrainingLean Facilitator Training

Page 20: Quality First – Manufacturing Execution System (MES)

LMS

Lear Internal Project Tracker (LIPT) allows all employees access to all projects

Notification set to Plant Champions when projects are deemed to have “Leveragability”

Project Leveraging and SharingProject Leveraging and Sharing

Page 21: Quality First – Manufacturing Execution System (MES)

LMS

President’s Operational Excellence Award

Measuring ROI Through Tailored MetricsMeasuring ROI Through Tailored Metrics

Drives plant accountability

Evaluates plants on common criteria

Points Points Points Points Points Assessment Score: Available Awarded Awarded Awarded Awarded

Q1 Q2 Q3A. Planning and Training

1. Strategic Planning2. Training3. Workshops

B. Continuous Improvement Projects1. Technical Merit & Control2. Leveraging Improvement

C. Plant Operations1. World Class Housekeeping2. Plan For Every Part3. Supermarkets4. Pull Systems5. Visual Management6. Value Stream Mapping7. Labor Optimization8. Total Productive Management

D. ResultsPlant PerformanceContinuous Improvement MetricsCustomer Dissatisfaction Issues

Q1 Q4Q2 Q3

Q4

President's Operational Excellence Assessment

Plant NameSummary - 2008

40.015.025.0

20.0

3.02.0

3.0

2.0

3.02.0

3.02.0

5.020.025.0

15.010.02.52.5

6

Advance Relentlessly

Page 22: Quality First – Manufacturing Execution System (MES)

LMS

Continuous Improvement Roadmaps

Measuring ROI Through Tailored MetricsMeasuring ROI Through Tailored Metrics

Identifies projects and priority (C&E matrix)

Encourages creativity vs capital investments

Whitby, Canada Plant

CY2003 SSD Continuous Improvement Incremental Project Chart(US$ Hard Savings Only)

Ergonomic

Black Belt / Resource

Project ID #or Tracking #

Type of Savings

(SS, VA, PP) Hyperion Code Project Description Status Start Date Finish Date

Est Ann. Hard

SavingsEst Ann.

Soft Savings

Guta, Eva/ Vozza Frank20024742A7T SS ssrisk Velcro Removal on Builds IPW 31-Mar-01 01-Jan-03 - Hunt, Joe SS ssc S&A Lear Dr. IPW 31-Dec-01 01-Jan-03 65,000 Vozza, Frank 200011DOP SS ssc Scrap Reduction IPW 02-Jan-03 01-Jan-03 65,000 Vozza, Frank 20012281DDP SS ssnon Optimize Energy Mngtmt LI 03-Jan-03 01-Jan-03 25,000

Chadwick, Chris 20001897D1P SS ssrisk Live Unload/ Load Optimization IPW 15-Jun-02 01-Jan-03 - Chadwick, Chris 2002.0742AT SS ssnon Buick Forklift Optimization LI 06-Jun-02 01-Apr-03 95,292 Chadwick, Chris 200298976AT SS ssnon Chevy Forklift Optimization LI 06-Sep-02 01-Apr-03 95,210 Chadwick, Chris PP pprisk Transfer Station LI 06-Sep-02 01-Jan-03 - Plant PP ppnon Direct Labour ( 20 ) Dec. 02 01-Jan-03 615,186 Plant PP ppnon Direct Fringes Dec. 02 01-Jan-03 337,737 Plant PP ppnon FGI System- Direct Labour (7) 01-Jun-03 01-Jul-03 103,534 Plant PP ppnon FGI System - Direct fringes 01-Jun-03 01-Jul-03 56,839 Plant PP ppc Worker's Compensation Dec. 02 01-Jan-03 193,548 Plant PP ppc Recruiting/ Training Dec. 02 01-Jan-03 32,258 Plant PP ppc Other Materials / Supplies Dec. 02 01-Jan-03 69,661 Hunt, Joe va varisk Chevy RSC Drawstring LI 04-Feb-02 28-Feb-03 - Hunt, Joe SS ssrisk Headrest Tubes During Inversion IPW 15-May-02 12-Dec-03 - Hunt, Joe va vanon Towel Bar Weld Process/ JRM Tube IPW 12-Feb-02 03-Jan-03 16,000 DMChadwick, Chris 2002867A15T SS ssnon Intermodal Transportation IPW 12-Feb-02 01-Mar-03 220,000 Chadwick, Chris 20024735D5P SS ssc GMX 367 Packaging- Lear Maple IPW 01-Aug-02 01-Oct-02 38,341 DMChadwick/ Hunt 20024735D5P SS ssc Camaco Milk Run IPW 15-Nov-02 03-Jan-02 216,200 Chadwick/ Hunt 20024735D5P SS ssc Sur Flo 367 Container Optimization IPW 01-Sep-02 20-Dec-02 68,000 DMChadwick/ Hunt 20024735D5P SS ssc Kitchener 367 Container Optimization IPW 01-Sep-02 20-Dec-02 7,800 FRTChadwick/ Hunt 20024735D5P SS ssrisk Camaco 367 Container Optimization IPW 01-Sep-02 20-Dec-02 - Chadwick/ Hunt 20024735D5P SS ssc Modineer 367 Container Optimization IPW 01-Sep-02 20-Dec-02 137,968 FRTChadwick/ Hunt 20024735D5P SS ssc Brown Container Optimization IPW 01-Sep-02 20-Dec-02 122,522 FRTChadwick/ Hunt 20024735D5P SS ssnon Mold Plas 367 Container Optimization IPW 01-Sep-02 20-Dec-02 67,017 Chadwick, Chris 20024735D5P SS ssnon Flow Rack System IPW 02-Oct-02 01-Jul-03 100,000

Chadwick, Chris 2001731FFID SS ssnon Buick Armrest remove Paint-Fixed IPW 01-Sep-02 01-Feb-03 10,636 Chadwick, Chris SS ssnon Chevy Headrest Bags IPW 01-Dec-02 01-Jun-03 70,000 Norman/Salwonchuk SS ssnon Cycle Count Process IPW 01-Sep-02 01-Mar-03 35,000 Hunt/ Tonner/Vozza 2002971B7ET SS ssnon Lear Grand Rapids Track Optimization IPW 31-Dec-01 125,000 Chadwick, Chris PP ppc Inbound Freight - Grand Prix IPW 01-Jan-01 25-Jan-03 - Plant PP ppnon Inbound Freight - Grand Prix ( FEB) IPW 01-Feb-03 22-Feb-03 - Mullin/ Johnston 200381444AP SS ssc Tears/ Rips 367 FSC IPW 14-Nov-02 17-Feb-03 - Naugle/ Huff 2002633DC4P SS ssc 70% Rear Door Scuff Reduction IPW 14-Nov-02 13-Jan-03 - Plant PP ppc Irvin Freight Save 15-Nov-02 17-Feb-03 321,449 FRT

Plant N/A SS Six Sigma Forecast AdjustmentPlant N/A VA VA/VE Forecast AdjustementPlant N/A PP Plant Performance Forecast Adjustment

Plant N/A SS ssunid Six Sigma Unidentified TaskPlant N/A VA vaunid VA/VE Unidentified TaskPlant N/A PP ppunid Plant Performance Unidentified Task

Plant N/A SS Six Sigma Contribution (Reserve Usage)Plant N/A VA VA/VE Contribution (Reserve Usage)Plant N/A PP Plant Performance Contribution (Reserve Usage)

3,310,198 -

Hyperion Codes: Status Column Legend:ssC Six Sigma New Implemented D = Define Phase VAI = VA internal

ssnon Six Sigma New Non-Implemented M = Measure Phase VAE = VA external, (came from a mega list)ssrisk Six Sigma New Risk in Forecast A = Analyze Phase SSE = generated from SSE workshop

ssunid Six Sigma Unidentified Task I = Improve Phase LE = Lean work shopvaC Va/Ve Implemented C = Control Phase KS = Generated from Knowledge swap

vanon Va/Ve Non-Implemented Completed LI = Leveraged in from another plantvarisk Va/Ve Risk in Forecast X - Canceled LO = Leveraged out to an other plant

vaunid Va/Ve Unidentified Task PW = Generated from In Plant work shopppC Plant Productivity Implemented

Page 23: Quality First – Manufacturing Execution System (MES)

LMS

Lean Assessment

Measuring ROI Through Tailored MetricsMeasuring ROI Through Tailored Metrics

Drives one Lean culture.

Plant Date

Sec # ScoreA1 3.1A2 2.7A3 2.5A4 2.7A5 2.8A6 3.0A7 2.3A8 3.0A9 3.0

A10 3.1A11 3.2A12 3.1A13 2.6A14 3.9A15 3.4

Goal Actual

Lean Assessment Summary

Andon

Workplace OrganizationAudio & Visual ManagementOperation Certification & SupportInternal Pull & Material Conveyance

5-Oct-2007

External Pull & Transportation SystemCentral Material StorageLean Containers & Packaging

ASSESSMENTSCORE

In-Process Quality Verification

3.0

LORDSTOWN

Standardized Work

2.00

63

Error Proofing / Poka-YokeQuick Changeover (SMED)

Section

Continuous Improvement Process (Kaizen)Problem Solving (PDCA)Total Productive Maintenance (TPM)

1.87

63

0..53

Inventory Turns

Hours / Vehicle set 0.77

Days on Hand

Lean Assessment Summary

0.00.51.01.52.02.53.03.54.0

Section

Sco

re

Page 24: Quality First – Manufacturing Execution System (MES)

LMS

Value Stream Mapping Current vs Future State. VA vs NVA via Value Added % (DOH vs VA hours) Identifies and eliminates constraints and waste in process to

optimize flow Blackbelt projects identified.

Value Stream MappingValue Stream Mapping

Page 25: Quality First – Manufacturing Execution System (MES)

LMS

Extended VSM From Supplier to customer Packaging, freight and inventory levels Warehousing Optimal manufacturing targets.

Value Stream MappingValue Stream Mapping

Fonseca, Arg SUV, UUV & TrucksLeather DOH - 3 daysFrqncy - 1 X per week Value - $ 235.6K6515 miles Frqncy - 3 X per weektrans time - 12 day Wkly Frgt - $ 4.3K Transit time - 38 hrscost of trip - $4810 Value in Trans - $118 K Cost per trip - $1437

dist. - 898 miles GroundFrqncy - 3 X per week

1st & 2nd RowsDOH - 1.8 daysValue - $ 313.2KFrqncy - 15 X per week

El Paso, Tx Wkly Frgt - $ 50K Transit time - 7 daysLeather Value in Trans - $1,219K Cost per trip - $2615

Frqncy - 4 X per day dist. - 2036 mls (566) Rail &Ground21 miles Frqncy - 15 X per week

trans time - 1/2 daycost of trip - $15

PcsOH - 190,407Value - 2,922,747

El Paso, Tx 1st, 2nd &3rd RowsLaminate Fabric DOH - 1 daysFrqncy - 2 X per day Value - $242.8K25 miles Frqncy - 8 X per weektrans time - 1/2 day Wkly Frgt - $ 25.6K Transit time - 6 days

cost of trip - $65 Chicago Value in Trans - $1,457K Cost per trip - $2256dist. - 1632 mls (162) Rail &Ground

Frqncy - 8 X per week

S. Teresa, NM Milliken - El Paso 4.1 days $466,902Laminate Fabric Foamex/Guil - S. Teresa 5.3 days $82,568Frqncy - 1 X per day Foamex/CGT - S. Teresa 9.1 days $31,05930 miles Foamex/Ath - S. Teresa 3.9 days $172,810

trans time - 1/2 day Eagle Ott. Fonseca - ARG 9.7 days $297,564 4.5 days on hand 1st & 2nd Rowscost of trip - $40 Eagle Ott. Jarudo - Mex n/a days $3,456 229,331 pc on hand DOH - 2.4 days

Eagle Ott. Bermudez - Mex 2.6 days $3,025 daily $OH - 3,476K Value - $ 256.8KSeton - El Paso 3.0 days $237,843 45,480 container/day Frqncy - 6 X per weekLear Carlisle - Carlisle PA 7.8 days $183,617 60 shipments /week Wkly Frgt - $ 18K Transit time - 6 daysCGT - Brandford, ONT 17.2 days $2,338 64,505 sq. ft Value in Trans - $647K Cost per trip - $2348Athol - Butner, NC 17.4 days $24,064 $27.1K monthly lease dist. - 1770 mls (300) Rail - Ground

Hrly cost -$4,275/week Frqncy - 6 X per weekS. Teresa, NM $1,505,246 Sal cost - $1,250/weekLaminate VinylFrqncy - 1 X per day30 miles

trans time - 1/2 daycost of trip - $10

1st & 2nd RowsDOH - 2.0 days

PcsOH - 38,924 Value - $147.8KS. Teresa, NM Value - 555,405 Frqncy - 7 X per weekLaminate Vinyl Wkly Frgt - $ 23.8K Transit time - 6 daysFrqncy - 1 X per day Value in Trans - $443K Cost per trip - $237730 miles dist. - 1785 mls (315) Rail - Groundtrans time - 1/2 day Frqncy - 7 X per weekcost of trip - $111

1st, 2nd &3rd RowsDOH - 1.5 days

Brampton, ON, CA Value - $ 311.9KFlatstock vinyl Frqncy - 12 X per weekFrqncy - 2 X per week Wkly Frgt - $ 39.3K Transit time - 6 daysmode - truck (Milkrun) Value in Trans - $620K Cost per trip - $25321979 miles dist. - 1516 mls (46) Groundtrans time - 3 day Frqncy - 12 X per weekcost -$3500 + $65

Carlisle, PA 1st, 2nd &3rd RowsCarpet DOH - 1.8 daysFrqncy - 4 X per week Value - $ 464.4Kmode - Intermodal Frqncy - 7 X per week2013 miles Transit time - 12 hrstrans time - 7 day Wkly Frgt - $ 15K Cost per trip - $1042cost -$1864 + $65 Value in Trans - $258K Ground

distance - 624 milesFrqncy - 7 X per week

Butner, NCFlatstock vinylFrqncy - 4 X per weekmode - truck (Milkrun)1830 milestrans time - 3 daycost -$3500 + $65

GMT 900 - Tr im - Ext ended VSM (High-Level Cur r ent St a t e)

Ajax

6515 Miles

Columbia City

830

862

830

862

Inventory $

$35,871 / week

66 trips

25 Miles

30 Miles

30 Miles

30 Miles

Freight

Loma Verde

El Paso, TX

Fenton1470 miles

Juarez

various days 4.5 days

21 Miles

La Cuesta

Freight minimal

$1,505,246

1840 Miles

2013 Miles

$3,160,000

1979 Miles

$4,763,285 $2,128,440

1.6 days4.0 days

61 trips

$176,970 / week

Silao

Arlington

Janesville

Rochester Hills

L.Carlisle

Milliken

Athol

Eagle Ottawa

CGT

Foamex/Athol

Foamex/CGT

Foamex/Guil

Seton

Loma Verde - Mat'l

JIT - Materials Deptj

La Cuesta & Juarez - Mat'l

Bulk TrimShipment

Direct Shipment

Reduction of Inventory

Elimination of Landa

Elimination of Loma Verde

Reduce days in loop

Direct Bulk trim shipment

Direct shipment to JIT

Warehouse in Midwest -

Detroit

Inter-modalshipments

Bulk to Arlington

Page 26: Quality First – Manufacturing Execution System (MES)

LMS

Results

Lear Montgomery – Assembly Plant of the year – Assembly Magazine