As some of you may know, each year, the Japan Institute of Plant Maintenance (JIPM) bestows Total Productive Maintenance (TPM) awards to some plants having satisfied rigorous screening criteria.
Thousands of plants from many countries apply for these prestigious awards. Until 1998, no US-based plant had earned one of those.
Four American plants were distinguished this year for being the first from this country to win the "TPM Excellence" award for plants having over 500 employees. This happened at the annual JIPM-TPM Conference last month in Atlanta.
The winners are:
1.- Hitachi Cable Indiana, Inc., New Albany, IN. This is their self description of the plant success:
HCI was established in 1987 and began production in 1988.
Since that time we have made significant progress toward expanding our capabilities and products.
Current HCI in-house monthly production totals: 1.4 million Brake and Power Steering Fittings. Over 700,000 Brake Hose and Power Steering Assemblies. Capacity for over 2 million Low Pressure Power Steering and Vacuum Brake Hoses (currently producing 120,000 hoses/month).
HCI Customer Support:
Strong commitment for continued efforts for both "in-house" capability improvement and other "Local Sourcing" efforts. (We are)The only U.S. Brake Hose supplier that produces the hose, the fittings, and couples the parts together! This provides HCI with an in-depth understanding of each of the various components regarding specifications, performance and the impact to each other.
In-house design (CAD-FEA) and prototype development with a detailed understanding of performance related issues.
HCI Production Expansion Plan:
1995, launch Power Steering High Pressure Hoses.
1996, increase production capabilities to over 1.2 million assemblies per month.
1998, manufacturing plant for Hydraulic Brake Hose.
Quality Recognition:
Recognition as a "ZERO DEFECT" supplier to Nissan and Mazda for five consecutive years, to Ford Motor Company for four consecutive years, and a similar quality history with our other (newer) customers.
HCI has received Quality Master Awards from Nissan, Quality Achievement awards from Mazda and SIA, Q-1 status from Ford and Zero Defects Supplier awards from each of our customers.
HCI Policy:
HCI's philosophy is: "Our people are our most important product"!
If we make our people the most important target of our development efforts, they will make quality parts. And, HCI will increase in out businesss due to our customer's success.
Hitachi Cable Indiana, Inc.
5300 Grant Line Road
New Albany, Indiana 47150
2.- Michigan Automotive Compressor, Inc., Parma, MI; this company is working in the development of components for automotive air conditioning. Subsidiary of Denso, a Japanese complex. We are expecting some extra information from them as well as from:
3.- Phillips 66 Co., Sweeny, TX
4.- Subaru-Isuzu Automotive, Inc., Lafayette, IN.
is a joint venture of Fuji Heavy Industries Ltd. and Isuzu Motors - Limited.
Located in Lafayette, Indiana. SIA was established March 17, 1987,and currently employs 3000 full time and temporary Associates.
(SUV 2,447, CAR 1,640)
(SUV 34,489,CAR 32,419
(SUV 58,352, CAR 57,945)
(SUV 66,397, CAR 57,626)
(SUV 76,888, CAR 47,116)
(SUV 99,873, CAR 54,002)
(SUV 99,514, CAR 80,660)
(SUV 96,124, CAR 98,474)
(SUV 84,712, CAR 102,180)
(SUV 132,000, Car 98,000)
The Lafayette, Indiana facility is located on a total of 832 acres, with 500 acres improved. The total Building area encompasses 2,456,104 square feet.
Total Production capacity is 18,000 units per month.
Administrative Office space 147,600 square feet; Stamping, 346,550 square feet; Body Assembly, 430,000 square feet; Paint, 905,093 square feet;
Trim & Final, 933,402 square feet.
Without TPM implementation, and other best manufacturing practices, this impressive development would have not been possible to achieve.
Screening for the awards is a detailed process involving both documentation and onsite visits. Activities scrutinized include the following:
TPM policies and objectives
TPM organization and management
Individual improvement
Autonomous maintenance
Planned maintenance
Quality maintenance
Product and equipment development and control
Training and development
Administration and supervision
Safety, sanitation, and environmental control and
TPM effectiveness assessment
TPMonLine acknowledges the effort of the people who made this accomplishment possible. We feel proud for having them as members of the TPM community.
