Rick is also the co-author of Creating Continuous Flow: an action guide for managers, engineers & production associates, also a Shingo Research prize winner. Rick learned the realities of manufacturing during 15 years at GM, beginning as an operator and working his way up to first line manager. He received his lean education at Toyota’s Georgetown, KY, plant, where he was a member of the startup team and an assembly manager. Rick continued his lean training at the Tsutsumi Assembly Plant in Toyota City, Japan. He pioneered the "reverse flow" process to achieve dramatic increases in operator efficiency. He also has extensive experience developing layouts that facilitate one-piece flow, operator flexibility, first-time-through quality, optimum uptime, and reduced capital investment.
Chris began his lean training on the assembly line at Toyota’s Georgetown, KY, plant where he learned the proper use of lean tools such as takt time, standardized work, production status boards, and the andon system. He continued his lean training at Toyota Tsusho America where he worked with returnable container systems, kanban systems, parts supermarkets, and milk runs. Chris, a six sigma green belt, also has been a production supervisor and a corporate buyer. He currently aids companies implementing lean through Harris Lean Systems.
Earl has 35 years extensive manufacturing experience. He began his career as fabrication operator and worked his way up to hold various management positions. Earl received his lean training as Materials Manager at the Johnson Controls plant in Georgetown, Ky., a tier one supplier to Toyota. He has spent the last twelve years helping companies in many different industries implement lean principles into their organizations. He has extensive experience in material flow, facility layout, cell design and administration processes. To learn more about Earl and his company, visit wilsonleanconceptsinc.com.
- Following Four Steps to a Lean Material-Handling System Leads to a Leap in Performance
A case study of two Delphi factories that methodically implemented a lean material-handling system for purchased parts.
- Toyota’s New Material-Handling System Shows TPS’s Flexibility
Art Smalley, author of Creating Level Pull, reports on Toyota's material-handling system for assembly areas that he saw in action at an engine plant in Japan.
- The Power of a Precise Process
Jim Womack's e-letter about the importance of precise processes.
- Making Materials Flow
This workshop will teach you how to create a material movement and handling system for purchased parts from the receiving door to the shipping door. It focuses on how to transition from a mass-production material-handling system to a lean system that reliably supplies purchased parts to continuous-flow cells, small-batch processing, and traditional assembly lines. This workshop uses a realistic manufacturing video and factory example to step you through the implementation sequence and the use of formulas, forms, and rules so you know “what to do Monday morning” when you return to work. You will also learn formulas for calculating the number of kanban cards, rules for designing internal routes and determining route travel times, and how to sustain and improve the system with standard work.
LEI Workbook set
Buy all six of LEI's workbooks together and save 15%. Learn how to implement lean at the process, plant, and entire value-stream level with these Shingo Award winning books.
Creating Continuous Flow & Making Materials Flow set
Creating Continuous Flow focuses in on the cell level to help you achieve true continuous flow at your critical pacemaker process. Making Materials Flow explains how to implement a lean materials-handling system that supports continuous flow.