Fifty-Eighth Meeting of the Advanced Manufacturing Forum

The Journey to Lean Continues....

October 20-21, 2005

Session Highlights

David AdairExecutive Vice President
Absecon Mills, Inc.
Cologne, New Jersey

Implementing Lean: From Concept to Results

Absecon Mills, a major contract upholstery manufacturer, showed how lean principles could be applied to any industry. David Adair discussed the company's successful start on their journey to a lean enterprise and the challenges and obstacles in that transformation. Adair discussed how basic lean initiatives apply 'cross-industry' and how reducing excess inventory and managing waste make lean implementation self-funding. An overview of funding options and employee training and involvement were included.

Absecon Mills Executive Summary (34KB pdf)

Jeff Ackerson
Plant Manager
Pella Corporation
Gettysburg, Pennsylvania

Managing for Daily Improvement

Pella Corporation, a leading producer of windows and doors, began their lean journey over ten years ago. However, the Gettysburg plant has been in operation only since 2003, producing the company's new line of vinyl windows and doors. Ackerson talked through Pella's overall lean journey and the Managing for Daily Improvement (MDI) methodology that Pella uses to sustain results.

Pella Corporation Executive Summary (37 KB pdf)

Jennifer Buchanan, Manufacturing Superintendent
Andrea Williamson, Manufacturing Manager
Christopher Boyce, Operations Supervisor
Wyatt Younts, Manufacturing Superintendent
Baxter Healthcare North Cove
Marion, North Carolina

Lean Value Streams

Baxter Healthcare's North Cove plant is the world's largest manufacturer of IV solutions in flexible containers. Baxter chose Lean as its operating strategy for their continuous improvement processes. Their presentation covered the team's successful value stream mapping exercises.

Baxter Healthcare Executive Summary (27 KB pdf)

John L. Barkhouse
Corporate Manager
Caterpillar, Inc.
Peoria, Illinois

Creating Sustainable Change - The Lean Transformation

Barkhouse provided a history of Caterpillar's Lean journey, and how that journey led to the development of the Caterpillar Production System, a system that was ultimately deployed throughout the company and into its supply chain.

Caterpillar Executive Summary (28 Kb pdf)

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