UB to Train Local Delphi Thermal Suppliers in Principles of Lean Manufacturing

BUFFALO, N.Y. -- The Center for Industrial Effectiveness (TCIE) at the University at Buffalo is administering a 20-month program to deliver lean manufacturing training and implementation support to 16 Western New York companies that are suppliers to Delphi Thermal's Plant in Lockport.

Empire State Development (ESD), the state's economic development arm, awarded TCIE a grant of $412,000 to fund the program, which is expected run through June 2004.

Lean manufacturing is a proven management approach that focuses on moving materials more rapidly through the pipeline, eliminating waste, reducing work in process and turning resources into profits more quickly.

TCIE will work with select Delphi suppliers to implement the elements of lean manufacturing, modeling the approach on Delphi Manufacturing System (DMS), Delphi's particular version of lean manufacturing. The DMS production system, which closely resembles the Toyota Production System, is designed to transform traditional mass-manufacturing operations to flow-based operations, and to identify and eliminate waste.

"The training consortium will be an excellent way for suppliers to achieve a working knowledge of lean principles, which address supplier excellence," said Jerry Griffin, Delphi purchasing director. "Delphi Thermal is committed to the removal of wasted actions and to a concentration on value-added activities, both keys to a company's well-being and success".

The 16 companies involved in the project all are key New York State-based suppliers of the Delphi Thermal's Western New York operations. The majority of the companies specialize in the production of injection-molded and metal-stamped parts, in addition to the assembly and shipping of parts for Delphi.

"Delphi will be re-evaluating its entire supply base over the next few years," said Marguerite Greco, ESD project administrator with the agency's Buffalo office. "Lean manufacturing will be a requirement in order for these consortium companies to remain suppliers to Delphi."

Companies participating in the project have received training in:

* Lean manufacturing executive overview

* Lean manufacturing overview

* Lean manufacturing assessment training

* Assessment workshops focusing on gap analysis and lean planning techniques

Over the next year, a team from TCIE will deliver in-depth, on-site assistance in implementing lean manufacturing initiatives within company facilities. Members include Joe Orcutt, a consultant specializing in lean manufacturing and the lead trainer for the program, who has directed a similar, supplier-based program for a large manufacturer; Al Hammonds, a TCIE staff member and lean enterprise expert, who will focus on on-site implementation, and Rakesh Nagi, associate professor of industrial engineering in the UB School of Engineering and Applied Sciences, who will lend technical support to the team. In addition, TCIE is providing grant administration and project coordination.

The Center for Industrial Effectiveness is a program of the UB School of Engineering and Applied Sciences. TCIE works effectively with companies to improve business practices and modernize products, processes and facilities.