Ford Executives Visit Federal-Mogul Facility for Lean Manufacturing Insights

Strategic Insights -

Ford executives, led by department manager Ed Kemmerling, recently visited Federal-Mogul Corporation's Greenville, Michigan, Powertrain Plant to benchmark constraint management practices and learn from the facility's expertise in lean manufacturing. The visit was part of Ford's five-day Production Systems Boot Camp program, which aims to improve product flow and reduce inventory levels. The Ford team spent three hours shadowing Greenville Federal-Mogul employees, observing firsthand how constraint management processes enable the plant to achieve nearly 100% on-time delivery with high quality ratings.

Key Takeaways:

  • Twenty-four Ford managers, union leaders, and supervisors visited Federal-Mogul's Greenville Powertrain Plant as part of a five-day boot camp program to study constraint management practices.
  • The Ford team spent three hours shadowing Greenville Federal-Mogul employees to gain insights into the plant's lean manufacturing processes.
  • The Federal-Mogul facility was selected by Ford as an example of excellence in constraint management due to its nearly 100% on-time delivery and high quality ratings.
  • Ed Kemmerling, Ford department manager, praised the Greenville facility's cleanliness, visual displays, and employee enthusiasm, stating that it was a well-run operation that influenced him to make changes at his own plant.
  • Mike Craig, Greenville plant manager, explained that Federal-Mogul has been working on constraint management for 10 years, eliminating waste and improving employee involvement through processes.
  • The Federal-Mogul Greenville Powertrain Systems Plant produces original equipment and replacement engine bearings for automotive and heavy-duty applications, employing 405 people and operating in a 210,000 square-foot facility expanded 17 times since 1940.

Statistics:

  • 24 Ford executives visited Federal-Mogul's Greenville Powertrain Plant as part of a five-day boot camp program.
  • 100% of Federal-Mogul's attempts to deliver on-time met the mark, with consistent high quality ratings resulting from their constraint management practices.
  • 10 years have passed since Federal-Mogul began focusing on constraint management to eliminate waste and improve employee involvement.
  • 405 people are employed at the Greenville Powertrain Systems Plant.
  • The plant operates in 210,000 square feet of space, expanded 17 times since its establishment in 1940.

Sources:

  • PRNewswire (2000)