VIDEO SERIES
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An Insider’s Look at Manufacturing Success The Shingo Prize award winning Manufacturing InsightsŽ video series gives you an inside look at manufacturing success. These programs feature industry experts and companies who generously share their experiences in adopting new technology, process improvements, and workforce development.
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TABLE OF CONTENTS LEAN MANUFACTURING Introduction to Lean Manufacturing.............................2 What Lean Means.........................................................2 Five S Factory Makeover ..............................................2 Building a Lean Culture...............................................3 Incorporating Lean: From the Factory to Front Office....3 The Human Side of Lean Manufacturing at TECHNICOLOR........................................................3 Green Lean: Achieving Outstanding Environmental Performance with Lean.......................4 Engineering a Lean Supply Chain................................4 A Lean Supply Chain at John Deere..............................4 Learning Lean Through Simulation..............................4 Breakthrough Kaizen Events........................................5 Training Within Industry...............................................5 Lean Product Development...........................................5 Mapping Your Value Stream.........................................6 Value Stream Mapping.................................................6 Kanban Systems..........................................................6 Continuous Improvement-Sustaining the Effort...........7 Visual Controls.............................................................7 Right-Sized Equipment................................................7 Single Piece Flow.........................................................7 Quick Changeover for Lean Manufacturing...................................................8 Setup Reduction ..........................................................8 Introduction to Lean Tooling.........................................8 Lean Tooling in Action .................................................9 Lean Accounting..........................................................9 ABC/ABM Understanding Manufacturing Costs...........9 Lean ITS.....................................................................10 Product Data Management Applications in Manufacturing.........................................................10 Lean Manufacturing in a Small Shop.........................10 Lean Manufacturing at Miller SQA.............................11 Lean Manufacturing at TAC Manufacturing...............11 Managing Teams in Manufacturing...........................11 Customer Focused Manufacturing.............................12 Flexible Material Handling.........................................12 Flexible Small Lot Production for JIT...........................12 Re-engineering the Manufacturing Enterprise...........12 Mistake Proofing: Achieving Zero Defects...................13
Poka-Yoke: Mistake Proofing......................................13 Total Productive Maintenance (TPM) Blitz..................13 TPM: Total Productive Maintenance............................13
TECHNOLOGY Design for Manufacture and Assembly (DFMA)..........14 DFM: Design for Manufacturing.................................14 Metal Forming Simulation..........................................14 High Speed Machining...............................................14 Minimum Quantity Lubrication...................................15 Micromachining.........................................................15 Advanced Grinding.....................................................15 Advanced Robotic Welding.........................................15 Lean Automation........................................................16 Affordable Automation for Small & Medium Facilities.................................................16 Machine Vision & Error Proofing.................................16 RFID: Tool Tracking Solutions.....................................16 Ergonomic Safety.......................................................17 Composites in Manufacturing....................................17 Medical Applications of Rapid Prototyping.....................................................17 Rapid Casting: Rapid Prototypes for Metal Casting Processes..........................................18 Rapid Manufacturing.................................................18 Reverse Engineering: 3D Data Capture......................18 Direct Metal Manufacturing.......................................19 Rapid Tooling, Rapid Parts.........................................19 Concept Modeling......................................................19 Manufacturing Alternative Energy Systems........................................................19 Nanomanufacturing...................................................20 Nanometrology...........................................................20 Structural DNA ..........................................................20
QUALITY The Cost of Poor Quality.............................................21 Failure Mode Effects Analysis (FMEA)........................21 Six Sigma...................................................................21 Supply Chain Management........................................22 Theory of Constraints.................................................22 Work Measurement.....................................................22
LEAN MANUFACTURING Introduction to Lean Manufacturing Explains the core philosophies behind lean manufacturing, providing insight into why so many companies are adopting lean principles to enhance productivity, improve quality, and increase profits. See examples of visual management, standardized work, as well as value-added and non-value-added activities. (16 minutes) Product ID: DV03PUB46 ................................. $120/Members: $108 What Lean Means George Koenigsaecker, president of Lean Investments, LLC, and a lean sensei for nearly three decades, gives an updated analysis of lean concepts as they relate to the operations of The Shingo Prizewinning company, Hearth & Home Technologies in Mount Pleasant, Iowa. Visit this lean company, witness the employee culture required to fuel its journey, and learn to combat first-time uneasiness with lean behavior by placing it in context with continuous improvement. (29 minutes) Product ID: DV07PUB12 ................................. $149/Members: $129 Five S Factory Makeover Five S stands for Sort, Set in order, Shine, Standardize, and Sustain. Great for anyone from novices to seasoned lean practitioners, this program shows you how to identify the “Seven Wastes,� by going through the process with two companies and includes interviews with those responsible for the success of the projects. Company case studies include Symmons Industries and Affordable Interior Systems. (21 minutes) Product ID: DV05PUB12 ................................. $120/Members: $108
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Building a Lean Culture Learn how to sustain your lean improvements and ways to ensure buy-in from employees at all levels of the organization. While fundamentally changing workplace culture is easier said than done, the HID Corporation is well on its way. See how the company built a sturdy foundation — teamwork, community involvement, and social interaction among employees — from which new improvement ideas continue to positively impact quality, cost, and delivery. (22 minutes) Product ID: DV06PUB15 ................................. $120/Members: $108 Incorporating Lean: From the Factory to Front Office A global leader in particle separation equipment, SWECO applied lean plant-wide, from the office to the loading dock. SWECO team leaders reveal the secrets for continuous improvement within their operation. See how they used a two-prong approach to apply lean, helping them to increase profits, improve quality, reduce costs, and better serve their customers. (24 minutes) Product ID: DV08PUB6 ................................... $149/Members: $129 The Human Side of Lean Manufacturing at TECHNICOLOR See how TECHNICOLOR Video Service was able to tap into the power of employee ideas to help their business thrive by building employee trust. Like so many organizations, TECHNICOLOR was facing competitive pressures and had to improve their performance or be eliminated. By motivating the employees to come up with ideas to make them more efficient, they were able to effect a positive change in their workplace culture and gain market share. Examples are based on improvements in facilities layout, improved visual controls, elimination of a noise problem, reduction of tape handling, and reduction of smaller wastes. (19 minutes) Product ID: DV04PUB15.................................. $120/Members: $108
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Green Lean: Achieving Outstanding Environmental Performance with Lean Expert consultants Dean Schroeder and Alan Robinson invite you inside Subaru Indiana Automotive to see how lean improvements led to breakthroughs in environmental performance. Realize the impact behind employee involvement as you see first-hand examples of waste reduction including reusing of packaging and recycling of raw materials. (29 minutes) Product ID: DV08PUB9 ................................... $149/Members: $129 Engineering a Lean Supply Chain This introductory program explores the business practice of supply chain collaboration and explains how companies are “leaning” their supply chain. Learn the steps to discover the waste in your supply chain and see how to define your company’s “core competencies.” Case studies by Greg Hutchins, principal for Quality Plus Engineering and the author of Supply Management Strategies, are featured. (17 minutes) Product ID: DV03PUB39 ................................. $120/Members: $108 A Lean Supply Chain at John Deere Look inside the successful partnership between John Deere and one of their suppliers, R&B Machining and Grinding Co., to see how continuous improvement in both companies led to profits in a competitive marketplace. (21 minutes) Product ID: DV03PUB32 $120/Members: $108 Learning Lean Through Simulation Experience a realistic lean experiment without the high cost or risk of failure. Recorded at the Lean Learning Center in Novi, Michigan, you’ll observe the different methods each team applied to solve a similar problem. Learn how lean is a process of improvement, and see how the application of lean principles and rules can increase efficiency, improve quality, and strengthen customer-supplier connections. (23 minutes) Product ID: DV03PUB70 ................................. $120/Members: $108
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Breakthrough Kaizen Events Experience an actual kaizen event at the Lantech Corporation where over 100 productivity, quality, safety, and ergonomics improvements were completed. Hear comments from several experienced kaizen leaders as they describe employee attitudes found in a successful event. The essential goals of kaizen are illustrated so you can solve problems and eliminate waste within your company. (19 minutes) Product ID: DV03PUB37 ................................. $120/Members: $108 Training Within Industry See how the four modules of TWI: job relations (JR), job instruction (JI), job methods (JM), and job safety (JS) work together to generate cooperation and positive employee relations, teach supervisors how to quickly train employees, establish and maintain standardized work, provide a framework for sustained continuous process improvement, and maintain a safe work environment. (30 minutes) Product ID: DV08PUB16 ................................. $149/Members: $129 Lean Product Development Authors and educators Michael Kennedy and Ron Mascitelli provide unique but synergistic approaches to lean product development implementation along with tips on how to avoid pitfalls and ensure success. Get started on your journey to dramatic reductions in timeto-market and create a greater value for your customers. Viewers hear practical, real-world experiences from several firms to help guide their own lean product development and deployment strategy. (29 minutes) Product ID: DV08PUB11 ................................. $149/Members: $129
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Mapping Your Value Stream See how the Donnelly Corporation used value stream mapping to reduce inventory and create one-piece flow in the assembly of automotive mirrors. Kanban card systems, andon lights, inventory trigger points, and other lean concepts illustrate the methods used to improve product quality and delivery. James Womack, PhD, president of the Lean Enterprise Institute, describes the power of current- and future-state value stream mapping. (33 minutes) Product ID: DV03PUB35 .................................. $280/Members $252 Value Stream Mapping Produced in partnership with the Greater Boston Manufacturing Partnership, we go inside Jotul North America to uncover the shop floor element behind this process. Witness the outcomes of a two-day training event led by Pat Wardwell, chief operating officer for GBMP, as you learn a three-step process of documenting flow to identify waste and uncover opportunities for improved quality, cost control, lead time, and customer value. (40 minutes) Product ID: DV07PUB11 ................................. $149/Members: $129 Kanban Systems Ideal as an introduction to the basic concepts of kanban, you’ll see what kanban systems are available, how they work, and where they’ll be successful. This program centers on how this lean tool supports inventory control to better respond to customer demands, promotes visual control, and reduces managerial and inventory costs. (26 minutes) Product ID: DV04PUB1 ................................... $280/Members: $252
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Continuous Improvement-Sustaining the Effort This program highlights the methods used by manufacturing companies to prevent their continuous improvement efforts from fading away. It also provides the reason most improvement programs fail and what you can do to keep your workforce motivated to improve. (38 minutes) Product ID: DV03PUB44.................................. $280/Members: $252 Visual Controls See how visual controls are developed and used in a factory environment to help identify production problems and improve productivity. Case studies at four leading companies show how to control inventory, schedule maintenance, and clearly mark machine and tool locations. We look at the typical worker reaction to using visual controls and illustrate the steps needed to help sustain the gains achieved after implementation. (26 minutes) Product ID: DV03PUB34 .................................. $280/Members $252 Right-Sized Equipment An exclusive look into Boeing’s commercial airplane plant and integrated aero structures division explains how right-sized equipment improved their lean process. Instead of large product batches that must be stored, right-sized equipment produces just the amount of product needed and errors in the process can be quickly exposed and eliminated. (26 minutes) Product ID: DV06PUB1 ................................... $280/Members: $252 Single Piece Flow Advance your own lean training initiative through the practical applications behind single piece flow. Industry insights from Conmed Linvatec, a world-class manufacturer of surgical equipment, focus on how the company transformed production of large batches to making only what its customers need, becoming more profitable, competitive, and responsive to the demands of the marketplace. (18 minutes) Product ID: DV06PUB13 ................................. $120/Members: $108
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Quick Changeover for Lean Manufacturing Study case examples of quick changeover in the plastic injection molding, metal stamping, and metal cutting industries. Learn how each reduced changeover times to be more responsive to customer needs as well as the benefits of reducing setup times, how to identify wasted time by analyzing your current routine, and the five common organizational procedures to follow when implementing quick changeover. (32 minutes) Product ID: DV03PUB33 .................................. $280/Members $252 Setup Reduction Follow a three-day journey at Plymouth Tube where Rick Feller, manager of manufacturing excellence, is your host for the company’s setup reduction kaizen. See how to lead a setup reduction event, measure your current methods, identify time elements within a setup, and learn what it takes to change and prove out methods. The program also covers team composition, equipment needs, encountering resistance, and achieving team consensus. (21 minutes) Product ID: DV08PUB10 ................................. $149/Members: $129 Introduction to Lean Tooling This program will help you organize your tooling so you can find every tool you need in less than 30 seconds. Get tooling ready faster so that setup time is minimized and be able to rely on your tools for precision, so inspection time can be eliminated. The program will also show you ways of reducing administrative tooling costs by demonstrating kanban systems for keeping track of tooling inventory. This program is designed to be used in conjunction with the Lean Tooling in Action video, which presents examples of lean tooling at four different companies. (18 minutes) Product ID: DV03PUB40.................................. $120/Members: $108
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Lean Tooling in Action First, you will see lean tooling at Lee Blake Precision Machining and see how they’ve integrated lean tooling into their daily work practices, saving a tremendous amount of time and money. Next, you will see Eaton Aerospace and learn how the 5S system and visual controls were used as they implemented lean tooling. Then you’ll visit K&A Machine & Tool, where a kanban system was used to control tooling insert usage. Lastly, at Classic Turning, you’ll see how employees are solving tooling and changeover problems through teamwork and continuous improvement. This program is meant to be used in conjunction with the Introduction to Lean Tooling video, which presents the five phases of implementing lean tooling. (26 minutes) Product ID: DV03PUB41.................................. $120/Members: $108 Lean Accounting Use this program to provide everyone in your organization with a common understanding of lean accounting and its impact on the road to becoming lean. See how lean accounting supports lean manufacturing by offering data that enhances continuous improvement, value stream analysis, and performance. Experts Brian Maskell and Orry Fiume outline ways to become a world leader in lean business management. Company case studies include Southco, Inc. and MarquipWardUnited. (32 minutes) Product ID: DV05PUB44 ................................. $255/Members: $229 ABC/ABM Understanding Manufacturing Costs This program shows how activity-based costing (ABC) and activitybased management (ABM) can help you zero-in on true product costs so you can use that data to optimize your competitive edge. It also demonstrates how ABC identifies and computes the cost of both activities and processes. You’ll see the many advantages ABC has over traditional accounting systems and hear ways to trace resources to activities and trace activities to parts, products, and distribution channels. Discover how to identify cost drivers! You’ll also see how ABM evaluates those activities performed to support concepts such as continuous improvement, total quality management, and business process re-engineering. (33 minutes) Product ID: DV05PUB13.................................. $120/Members: $108 800.733.4763 | sme.org/mi
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Lean ITS Watch how one company overcame skepticism to inspire success. Produced in co-operation with the Association for Manufacturing Excellence (AME), employees from Kimberly-Clark, and lean expert Jean Cunningham openly discuss how they implemented lean principles to reduce waste in existing information technology systems (ITS). Candid interviews reveal and celebrate the realistic expectations of adopting a lean culture focused on value-added customer service. (50 minutes) Product ID: DV10PUB2 ................................... $149/Members: $129 Product Data Management Applications in Manufacturing Learn how product data management (PDM) can help companies get products to market faster, help keep design costs down, and provide data to field service personnel with more accuracy. You’ll see where the hidden danger spots are in a PDM system, as well as the many benefits obtained through an effective PDM operation. Case studies at leading companies examine many uses of a PDM system, including reduced product development time, better communication, and assistance with ISO 9000 certification. (37 minutes) Product ID: DV04PUB14.................................. $120/Members: $108 Lean Manufacturing in a Small Shop Witness how lean manufacturing helped Peterson Pacific Corporation reduce the time it takes to manufacture new machines. Learn how simple changes made for a more efficient plant layout and added flow to their assembly process. Interviews with key managers and supervisors illustrate how they selected business improvement areas and the problems that slowed down their initial application of lean. (28 minutes) Product ID: DV07PUB7 ................................... $120/Members: $108
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Lean Manufacturing at Miller SQA This program examines the lean manufacturing principles at Miller SQA, an office furniture company. Miller SQA has applied lean principles in a mass customization market to give their customers exactly the furniture they need when they need it. Continuous improvement is encouraged by presenting the benefits to all employees through lean events that allow different people from all parts of the company to examine the work area and make suggestions. In addition, a pull production control system maintains inventory levels at the assembly area so no more than two hours of parts are ever in the work cell ready to be assembled. One-piece-flow, cellular manufacturing, and strong visual controls are integrated into a sophisticated information technology system to help reach the company goal of 100% on time shipment of customer orders. (17 minutes) Product ID: DV03PUB47.................................. $120/Members: $108 Lean Manufacturing at TAC Manufacturing This program examines the successful lean manufacturing practices at automotive supplier, TAC Manufacturing. TAC Manufacturing is a subsidiary of Tokai Rica and their production philosophy is based on the Toyota Production System. Many lean principles are followed such as just-in-time parts delivery, pull production control, and visual controls. The team-based workplace culture creates highly motivated workers capable of meeting all customer demands. Supplier confidence is maintained by careful selection and frequent communications to keep inventories of all materials ready for processing when needed. (13 minutes) Product ID: DV03PUB48.................................. $120/Members: $108 Managing Teams in Manufacturing Avoid the pervasive pitfalls that often limit team performance and learn why team-based organizations almost always out-perform traditional top-down organizations. A case study of Hewlett-Packard illustrates how this team-based organization helps break down adversarial relationships between departments, production stages, and unions and management. (35 minutes) Product ID: DV03PUB105 ............................... $280/Members: $252
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Customer Focused Manufacturing This program presents the innovative techniques used for creating a highly flexible workforce and details the steps used when implementing a cell. See how Milwaukee Electric Tool Corporation successfully transformed to a more flexible, short lead-time system through cellular manufacturing, kaizen, and just-in-time production techniques resulting in remarkable improvements in productivity and profitability. (30 minutes) Product ID: DV03PUB53 ................................. $280/Members: $252 Flexible Material Handling This program looks at how material handling can be minimized, automated, or avoided to provide immediate cost savings. Four case studies describe material handling systems at Lexmark, Chrysler, Ford, and Electrolux. (28 minutes) Product ID: DV03PUB104 ............................... $280/Members: $252 Flexible Small Lot Production for JIT See how Roll Forming Corporation realigned equipment into cells based on three primary customer types in three months. Next, you’ll visit Joy Technologies to see how a machining cell manufactured by Milacron is monitored by a cell controller to reduce lead-time from four weeks to one week and dramatically cut inventory on hand. At Lockheed Aeronautical Systems Company, you’ll see how a flexible machining system is used to produce quality airframe components in lot sizes of one. (25 minutes) Product ID: DV03PUB107................................ $120/Members: $108 Re-engineering the Manufacturing Enterprise Understand how customer-driven production challenges are met through re-engineering the manufacturing enterprise through case studies with Black & Decker, Aeroquip Corp., and Himont Corp., In addition, you’ll learn critical success factors and performance measures and how to think more creatively about your competitive position. Cross-functional teams replace top-down management, core business processes replace departmental functions, employees are empowered to effect changes, flexibility and rapid response become paramount, and most importantly, the customer becomes a full-fledged partner in your organization. (36 minutes) Product ID: DV03PUB103................................ $120/Members: $108
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Mistake Proofing: Achieving Zero Defects Explore how poka-yoke is implemented and in what direction it has led various manufacturers. See how several leading companies developed systems to answer key questions in the mistake-proofing process. (30 minutes) Product ID: DV03PUB52 ................................. $280/Members: $252 Poka-Yoke: Mistake Proofing Examine the modern and practical methods of mistake proofing or “poka-yoke.” We visit Saline Plastics, ConMed Linvatec, and ESYS to see how the use of mistake proofing techniques can help reduce costs, increase quality, and accelerate customer delivery time. The commonplace examples outlined in the program provide a perfect training tool for anyone wanting to build a more reliable and predictable improvement process that can easily integrate with other business procedures. (31 minutes) Product ID: DV08PUB8 ................................... $149/Members: $129 Total Productive Maintenance (TPM) Blitz Watch what happens as team members from the Modern Drop Forge Company emerge from a four-day total productive maintenance kaizen event to identify potential problems, determine root causes for underperforming equipment, and brainstorm improvement ideas. You’ll gain predictive, preventive, and productive maintenance techniques that can bring an end to crisis maintenance. (31 minutes) Product ID: DV10PUB1.................................... $149/Members: $129 TPM: Total Productive Maintenance This program demonstrates how predictive and preventive maintenance techniques can end crisis maintenance. You’ll see how total productive maintenance (TPM) keeps equipment operating at design specifications and gets more output from smaller facilities. Case studies at facilities include Delco Remy, Loran Cassettes and Audio Products, and Miller Brewery. (46 minutes) Product ID: DV03PUB68.................................. $280/Members: $252
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TECHNOLOGY Design for Manufacture and Assembly (DFMA) This video features an interview with Nicholas Dewhurst of Boothroyd Dewhurst, who explains the concepts and use of DFMA in product analysis to help viewers understand cost drivers and the interaction of the individual pieces within the product to optimize design, manufacturability, and assembly. Companies case studied include MDS-SCIEX and Plug Power. (30 minutes) Product ID: DV05PUB2 ................................... $280/Members: $252 DFM: Design for Manufacturing Go inside Storage Technology, where DFM was used to cut cost 86% and reduced the part count from 119 to 36. Viewers also see how DFM was applied to large hydraulic cylinders at Caterpillar, Inc. At Xerox, DFM was used to redesign a paper feed guide with fewer parts. And, at IBM, standardized components helped to expedite product development. (43 minutes) Product ID: DV03PUB50 ................................. $280/Members: $252 Metal Forming Simulation Get an exclusive look into the innovative applications of metal forming simulation that are helping companies use less material to create better stamping dies, leading to more reliable tooling. For those involved in product design, die design, stamping, and forming, see inside Riviera Tooling Co. in Grand Rapids, Michigan for real-world application of this technology. (22 minutes) Product ID: DV06PUB2 .................................. $120/Members: $108 High Speed Machining High speed machining has been gaining acceptance due to the advances that encompass high speed machining centers, tooling, programming, and software. Go inside Trutron Corp., Protomatic Inc., Gosiger 3D, and Metlfab Inc., to see how these four unique companies successfully implemented high speed machining systems to increase operation efficiencies, customer turnaround, and cost savings. (36 minutes) Product ID: DV06PUB8 ................................... $280/Members: $252
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Minimum Quantity Lubrication See how four distinct manufacturers, who had once relied on traditional flood-coolant methods, found minimum quantity lubrication systems to reduce high handling, cleaning, and disposal costs, as well as hazards to plant workers’ skin and lungs. Ford Motor Company, Amerimax, Advanced Mold, and World Machinery & Saws System Company share their successes in eliminating these costs and hazards, while increasing production rates and tool lifetimes. (39 minutes) Product ID: DV07PUB10 ................................. $280/Members: $252 Micromachining Micromachining comprises a growing collection of technologies used to create micro-electromechanical systems (MEMS) and new microfluidic and micro-optic devices. See how four companies are using micromachining to increase the accuracy of cutting and drilling operations, create light- and fluid-transmitting micro-channels within glass, produce fluid-handling components on silicon wafers, and build 3D MEMS devices. (32 minutes) Product ID: DV05PUB3.................................... $280/Members: $252 Advanced Grinding Examine how recent advancements in grinding can be optimized to improve surface-finish and accuracy in ground parts. See the use of advanced cylindrical grinding techniques, tool and cutter grinding, and the abrasive belt grinding of parts coated with High Velocity Oxygen Fuel (HVOF) – a thermal spray coating containing a high percentage of carbide. (31 minutes) Product ID: DV08PUB15 ................................. $149/Members: $129 Advanced Robotic Welding Uncover the innovations that have expanded this process beyond robotic resistance spot welding and arc welding. See how high-volume manufacturers of vehicle structures use laser and hybrid welding to make fast, reliable welds. Visit Harley Davidson and Dana Corporation to see how they’re creating lightweight structures for high-performance vehicles, and hear from Comau and Weld Solutions, Inc. as they share the latest advancements in laser and hybrid plasma welding. (41 minutes) Product ID: DV07PUB13 ................................. $149/Members: $129 800.733.4763 | sme.org/mi
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Lean Automation Explore the practical application of automation and see how it can be more effective when used with lean principles. Three companies share their experiences: Opthonix, a mass-manufacturer of customized eyeglass lenses; Vickers Engineering, a metal-cutting and fabrication manufacturer; and Aztec Manufacturing whose automated work cells combine robots with a CNC metalcutting machine. (24 minutes) Product ID: DV08PUB14 ................................. $149/Members: $129 Affordable Automation for Small & Medium Facilities Learn how Factory Five Racing, Supreme Corporation, and Peterson Manufacturing dealt with issues involving automation justification, planning, and implementation. These shops automated specific material-removal and assembly processes using the most flexible of automation systems – robots. Case studies show that automation decisions not only depend on product type, variety, and volume, but also on a shop’s capability and culture. (31 minutes) Product ID: DV06PUB14 ................................. $280/Members: $252 Machine Vision & Error Proofing Written by renowned industry expert Nello Zuech, you will see how BorgWarner, Ford Motor Company, and Gold Kist each applied different approaches to machine vision, the challenges they faced, and the solutions they developed in their plants. (31 minutes) Product ID: DV06PUB10 ................................. $280/Members: $252 RFID: Tool Tracking Solutions Manuel A. Pachano explains the infrastructure and technology behind RFID and its real-world practical applications, challenges and advantages for supporting quality and productivity. Traxle Manufacturing, ABSKY, Witman, and Nordam show how they use RFID to maintain and communicate activity history of precision tools, restock and repair inventory, track data on high-value composite layup molds, and incorporate RFID on the end of a robotic tooling system for quick changeover and error-proof tooling. (35 minutes) Product ID: DV08PUB7 ................................... $149/Members: $129
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Ergonomic Safety This program will explain the benefits of a successful ergonomic safety program. Interviews with Tom Leamon, Liberty Mutual and Marvin Dainoff, director of the Center for Ergonomics at Miami University, give you an understanding of the problems with ergonomics in industry. Case studies in this program are at John Deere in Iowa, Lockheed Martin in Texas, and Winpak Portion Packaging in Illinois. You will learn about a ten-point ergonomic approach that integrates known human performance with the workplace and product design. (31 minutes) Product ID: DV03PUB55.................................. $280/Members: $252 Composites in Manufacturing See how pultruded fiberglass and polyester are used in the netshape production of ladder rails at Glastrusions and how Century Plastics uses a sheet-molding compound of fiberglass and polyester resin for a water tank seal. You will also see how filament winding of carbon fiber and epoxy on an open-end cylinder is used at Structural Composites Industries. (31 minutes) Product ID: DV03PUB118................................ $120/Members: $108 Medical Applications of Rapid Prototyping Direct Dimensions shows you how 3D scanning technology and rapid prototyping are used to make aesthetic prosthetics. You’ll also meet the John Hopkins University medical illustrators and modelers who give the prosthetics their realistic look. Biomet Corp. demonstrates how CT and MRI scans are converted into rapid prototyped models for making custom patient-matched implants, and The Medical University of South Carolina explores how rapid technologies are used to build replacement tissues from living cells. (29 minutes) Product ID: DV07PUB8 ................................... $280/Members: $252
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Rapid Casting: Rapid Portotypes for Metal Casting Processes Scripted by renowned industry specialist Todd Grimm, this program shows how rapid casting and its various techniques have become an indispensable part of modern manufacturers’ ability to shorten lead times. Case studies look into the evolution of rapid casting technology and evaluate flexibility for producing complex, finely detailed castings that eliminate the need for hard tooling, thus reducing production costs and time to market. (36 minutes) Product ID: DV09PUB7 ................................... $149/Members: $129 Rapid Manufacturing Hear industry insights from 12 seasoned experts, each bringing a fresh perspective on the practical applications and vision of future rapid technologies. Program covers Advatech and Loughborough University in the UK to see how rapid manufacturing is transforming the design practices, processes, and business models across industries. This program also features real products currently manufactured using rapid processes and discusses the role of direct metal in rapid manufacturing. (32 minutes) Product ID: DV07PUB6 ................................... $280/Members: $252 Reverse Engineering: 3D Data Capture Introduces a broad range of applications including visualization, documentation, design, analysis, and inspection. Coverage also includes both laser and white light scanners along with discussions of their benefits and limitations over portable and stationary CMMs. You’ll go inside Roush Manufacturing, U.S. Army, Realadi, GKS Inspection Services, and Direct Dimensions to learn from those who are using practical applications of 3D, digital data capture. (31 minutes) Product ID: DV06PUB9 ................................... $280/Members: $252
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Direct Metal Manufacturing Scripted by industry expert Todd Grimm, this program illustrates what happens when innovative companies capitalize on direct metal manufacturing to make dramatic changes to the way parts and tooling are designed. Highlighting achievements at Morris Technologies, Synergeering Group, DME, and The POM Group, you’ll see how direct metal technology helped them to create molds and products direct from CAD data. (29 minutes) Product ID: DV05PUB14 ................................. $280/Members: $252 Rapid Tooling, Rapid Parts This program shows how CAD/CAM advancements in rapid prototyping allows you to move quickly from CAD/CAM concepts to hard tooling via rapid prototyping methods to make “ready-to-test” parts. You’ll also see rapid prototyping acceleration beyond fragile plastic constructions that show form and only mimic function to actual metal or engineered plastic parts from rapid tooling. (41 minutes) Product ID: DV03PUB120................................ $120/Members: $108 Concept Modeling This program takes an in-depth look at three machines to illustrate how engineers are adapting their approach to new product development. After witnessing each system in action, you’ll have a solid understanding of the technology and be better prepared for the changes it brings to product development. (23 minutes) Product ID: DV03PUB119 ............................... $280/Members: $252 Manufacturing Alternative Energy Systems Explore three unique companies that are taking advantage of alternative energy technologies to learn how advanced manufacturing and engineering processes can provide support for alternative energy systems and make a significant impact in cost reduction, performance improvement, reliability, and the product life cycle. (29 minutes) Product ID: DV05PUB40 ................................. $280/Members: $252
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Nanomanufacturing See first-hand how nanomanufacturing is ushering in the next Industrial Revolution with radically precise, less expensive, flexible methods of manufacturing. This program shows the current, nearterm, and future applications of molecular nanotechnology (MNT). Go inside Zyvex, NanoInk, Nanorex, General Dynamics, and NASA, as we speak with the world’s leading experts on nanotechnology. (37 minutes) Product ID: DV06PUB11.................................. $280/Members: $252 Nanometrology Travel to NIST, FEI, and the University of Michigan’s Electron Microbeam Analysis Laboratory (EMAL) to learn how scanning probe microscopy, scanning electron microscopes, and other advanced instruments are aiding the production of high-performance, nanoenabled products. (37 minutes) Product ID: DV08PUB12 ................................. $149/Members: $129 Structural DNA Structural DNA begins by highlighting the four stages of nanotechnology: static nanostructures, active nano devices, nano machines, and simple nano systems productive nano systems. This foundation provides the context to explore the four primary approaches to building productive nano systems. Discover how researchers are harnessing the structural and informational components of DNA to develop methods of altering molecules under programmable control to generate self-replicating productive nano systems. (30 minutes) Product ID: DV08PUB13.................................. $149/Members: $129
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QUALITY The Cost of Poor Quality This program looks at the cost of achieving quality, the cost of failing to achieve quality, and the cost of building in too much quality. It will also examine what drives those costs and what can be done to control them. You’ll learn effective ways to analyze the cost of quality data and the pitfalls to avoid, methods of eliminating the effects of poor quality, and a strategy for meeting total customer satisfaction. Case studies at the Merix Corp., IBM, and the Copeland Corp. show you successful strategies for reducing poor quality costs. This video is a must view for management, quality supervisors, and production managers looking to improve their company’s competitiveness. (35 minutes) Product ID: DV03PUB51.................................. $280/Members: $252 Failure Mode Effects Analysis (fmea) Quality standards like ISO-9000 and QS-9000 require FMEA on all new products. To shorten development cycles, many different experts are involved in the design and testing phases of new products. Give your design teams a good understanding of the importance of risk reduction, how FMEA will keep track of these responsibilities, and how FMEA is used to distinguish between product and process risk. (13 minutes) Product ID: DV03PUB38 ................................. $120/Members: $108 Six Sigma Discover the difference between Six Sigma and other quality programs, and how Six Sigma is used to find solutions to difficult problems. Company case studies include Gretag Imaging, Ortho Clinical Diagnostics, and Lockheed Martin. (29 minutes) Product ID: DV03PUB36 ................................. $280/Members: $252
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Supply Chain Management Information technology is used to gather real-time data to provide meaningful management information for maintaining suppliercustomer relationships. We show how companies have used real-time information systems to track sales and inventory. Detailed interviews shed insight into dramatically reducing finished goods inventory while providing new products to customers. (30 minutes) Product ID: DV03PUB43 ................................. $280/Members: $252 Theory of Constraints This program introduces the theory of constraints and demonstrates how it is applied in production scheduling to meet customer demand. Three companies that have successfully applied the theory of constraints demonstrate how the theory’s five focusing steps can infuse continuous improvement into the culture of an organization. Companies visited include Brenco, Dixie Iron Works, and Monroe Table Company. (35 minutes) Product ID: DV03PUB45.................................. $280/Members: $252 Work Measurement Learn work measurement practices and see how manufacturers are using them to measure productivity improvements. Go inside Cooper Instrument Corporation and MacGreggor Golf to gain insights into a work measurement system to develop standards and generate routings. Cramerton Automotive shows how they use work-sampling techniques and Kohler explains how work measurement is used to establish and correct standards for both direct and indirect labor. (30 minutes) Product ID: DV03PUB54 ................................. $280/Members: $252
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INDEX A–C
ABC/ABM Understanding Manufacturing Costs............................................9 Advanced Grinding......................................................................................15 Advanced Robotic Welding..........................................................................15 Affordable Automation for Small & Medium Facilities.................................16 Breakthrough Kaizen Events.........................................................................5 Building a Lean Culture................................................................................3 Composites in Manufacturing.....................................................................17 Concept Modeling.......................................................................................19 Continuous Improvement-Sustaining the Effort............................................7 Cost of Poor Quality, The.............................................................................21 Customer Focused Manufacturing..............................................................12
D–F
Design for Manufacture and Assembly (DFMA)...........................................14 DFM: Design for Manufacturing..................................................................14 Direct Metal Manufacturing........................................................................19 Engineering a Lean Supply Chain.................................................................4 Ergonomic Safety........................................................................................17 Failure Mode Effects Analysis (FMEA).........................................................21 Five S Factory Makeover................................................................................2 Flexible Material Handling..........................................................................12 Flexible Small Lot Production for JIT............................................................12
G–L
Green Lean: Achieving Outstanding Environmental Performance with Lean...............................................................................4 High Speed Machining................................................................................14 Human Side of Lean Manufacturing at TECHNICOLOR, The...........................3 Incorporating Lean: From the Factory to Front Office.....................................3 Introduction to Lean Manufacturing..............................................................2 Introduction to Lean Tooling..........................................................................8 Kanban Systems...........................................................................................6 Lean Accounting...........................................................................................9 Lean Automation.........................................................................................16 Lean ITS......................................................................................................10 Lean Manufacturing at Miller SQA..............................................................11 Lean Manufacturing at TAC Manufacturing................................................11 Lean Manufacturing in a Small Shop..........................................................10 Lean Product Development............................................................................5 Lean Supply Chain at John Deere, A..............................................................4 Lean Tooling in Action...................................................................................9 Learning Lean Through Simulation...............................................................4
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INDEX M–Q
Machine Vision & Error Proofing..................................................................16 Managing Teams in Manufacturing............................................................11 Manufacturing Alternative Energy Systems.................................................19 Mapping Your Value Stream..........................................................................6 Medical Applications of Rapid Prototyping..................................................17 Metal Forming Simulation...........................................................................14 Micromachining..........................................................................................15 Minimum Quantity Lubrication....................................................................15 Mistake Proofing: Achieving Zero Defects....................................................13 Nanomanufacturing....................................................................................20 Nanometrology............................................................................................20 Poka-Yoke: Mistake Proofing.......................................................................13 Product Data Management Applications in Manufacturing.........................10 Quick Changeover for Lean Manufacturing...................................................8
R–T
Rapid Casting: Rapid Prototypes for Metal Casting Processes....................18 Rapid Manufacturing..................................................................................18 Rapid Tooling, Rapid Parts..........................................................................19 Re-engineering the Manufacturing Enterprise............................................12 Reverse Engineering: 3D Data Capture.......................................................18 RFID: Tool Tracking Solutions......................................................................16 Right-Sized Equipment.................................................................................7 Setup Reduction............................................................................................8 Single Piece Flow..........................................................................................7 Six Sigma....................................................................................................21 Structural DNA............................................................................................20 Supply Chain Management.........................................................................22 Theory of Constraints..................................................................................22 Total Productive Maintenance (TPM) Blitz...................................................13 TPM: Total Productive Maintenance.............................................................13 Training Within Industry................................................................................5
U–Z
Value Stream Mapping..................................................................................6 Visual Controls..............................................................................................7 What Lean Means..........................................................................................2 Work Measurement......................................................................................22
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