Monday, April 23
12:00 pm - 3:00 pm

Allison Transmission, Inc is the leading producer of commercial-duty automatic transmissions, hybrid-propulsion systems, and related parts and services for on-highway vehicles, military vehicles, and off-highway equipment. The site, in total, is over 3.2 million square feet, has approximately 2700 employees, and is ISO/QS 9000 and ISO 14001 certified.

What you will see and learn about:

• newest facility within the site -- the manufacturing and assembly of the 1/2000 Series transmission

• the evolution the site has experienced migrating from a "batch-style" manufacturer toward a more "competitive-style"

• Allison Transmission Global Manufacturing System

• lean manufacturing improvements which can be incorporated in a "brownfield" site (97 years old)

• many work-in-progress initiatives that focus on reducing the seven wastes within manufacturing

• inventory control concepts that have saved millions of dollars since their inception and the use of kanban to signal material delivery

• the Allison Transmission "Fast Response" Quality System (24 hour corrective action process) which depicts accountability both within the facility and the supplier base

Note:

• Closed-toe shoes must be worn. No high-heels.

• No cameras are permitted.

****** PLANT TOUR IS FULL******

Monday, April 23
7:30 am - 12:00 pm

Carlisle Brake & Friction is a leading solution provider for high performance and severe duty brake, clutch and transmission applications. Products produced at the Bloomington facility include braking system components for the construction, mining and wind industries. Some friction processing is also done at the facility.

What you will see and learn about:

• Transformation into a visual factory and implementation of the Carlisle Operating System (COS)

• COS is their enterprise-wide operating system that uses lean principles such as:

  • Kaizen

  • Progressive 6S

  • Build to TAKT

  • Standard Work

  • Single-Piece Flow

  • Set-Up Reduction

  • Pull

  • Manage for Daily Improvement

  • Kanban

  • Total Productive Maintenance

• Other continuous improvement tools used within the COS include:

  • Visual Management of performance

  • SQDC (Safety, Quality, Delivery, Cost)

  • Poka-yoke

  • Training to Standard Work

  • Sigma-Kaizen

  • Process Capability Analysis

  • Root Cause-Correction Action

Note:

• Business casual attire

• Hearing protection and eye protection mandatory

• Closed-toe shoes must be worn.

Monday, April 23
7:00 am - 12:00 pm

Clabber Girl Corporation is the leading manufacturer of baking powder in the nation. The facility also produces Rumford®, Davis®, Fleischmann's™, and the Royal® brand dessert mixes. The company exports to more than 40 different countries around the globe, with distribution in North, South and Central Americas, Caribbean, Africa, Asia and the Middle East.

With food allergies on the rise, Clabber Girl became the first manufacturing facility in the United States to implement a peanut-free allergen protocol.

What you will see and learn about:

• A facility in the beginning phases of their Lean Manufacturing journey that has implemented or is in the process of implementing:

  • 5S

  • VSM

  • Kaizen events

  • SMED

• The first manufacturing facility in the United States to implement a peanut-free allergen protocol -- no products containing peanuts or peanut proteins are permitted in the manufacturing facility AND all ingredients must be verified by their manufacturers as containing no peanuts proteins.

• The "Callberation" Project -- Clabber Girl has partnered with Indiana State University to allow students to engage in practical learning situations in a manufacturing environment. University juniors and seniors are led by their professor and work in conjunction with Clabber Girl team members on specified projects such as process mapping and kitting strategies.

• Safe Quality Food (SQF) certification

• SWAT (Strategic Winning Actions & Tactics) Initiatives - reported on monthly at management meetings and progress is continuously tracked

Note:

• Shoe coverings are required (will be provided by Clabber Girl)

• Hairnets are required in all manufacturing areas and Beard nets must be worn in designated areas (both will be provided by Clabber Girl)

• Disposable lab coats must be worn (will be provided by Clabber Girl)

• All jewelry and any loose objects must be removed before access to any production area will be permitted. Exceptions to this policy are medical alert necklaces which are to be worn under the shirt and wedding bands without stones.

• Open toed shoes and shoes with a heel greater than 3/4" will not be allowed in manufacturing areas.

• Picture identification required

• Visitors may be permitted to carry cell phones in manufacturing areas, but phones must be stored on or below the waist. Cell phones are to be in the owner's possession at all times and are not permitted to be placed on manufacturing equipment or materials.

• Personal items are not to be stored above the waist. All handbags and loose articles of clothing will need to be removed and secured in an office or on the motorcoach until the visit has concluded.

• Peanuts and Peanut Products are prohibited in any form in the manufacturing facility

Monday, April 23
11:45 am - 4:15 pm

Cummins Inc., a global power leader, is a corporation of complementary business units that design, manufacture, distribute and service engines and related technologies, including fuel systems, controls, air handling, filtration, emission solutions and electrical power generation systems.

The Cummins MidRange Engine Plant (CMEP), located in Columbus, IN, is a 587,904 sq. ft. facility that produces the Cummins “B” series engine. Originally built in 1972 as a miscellaneous machining facility, CMEP shipped their first “B” engine in 1991 and their 1,000,000th in April 2003, with current volumes now exceeding 120,000 engine systems per year. The “B” engine is most commonly used to power 2500/3500 Dodge Ram HD pickup trucks, as well as vehicles manufactured by Ford and Freightliner.

What you will see and learn about:

• Visual management tools

• Training tools

• Problem solving

• Standardized work

• Kaizen activity

Note:

• No sleeveless shirts/dresses, no shorts, no open-toed shoes, and no high heels. 

• Cameras or other equipment capable of taking photos are not allowed. 

• Cell phones are not allowed on the shop floor.

• Safety glasses with side shields must be worn at all times, and can be provided; tinted glasses are not allowed. 

• Canes and walkers are not permitted on shop floor.  If assistance in walking is needed, please notify conference management at least 2 weeks in advance to arrange for special assistance at the plant.

Monday, April 23
1:00 pm - 5:00 pm

Endress+Hauser is recognized as a leading supplier of industrial measurement and automation equipment, providing services and solutions for industrial processes all over the world. The campus encompasses the following facilities that will be seen on the tour: Endress+Hauser Flowtec AG, Division USA -- Flow measurement systems; Endress+Hauser Wetzer (USA), Inc. -- Temperature measurement systems; and Endress+Hauser (USA) Automation Instrumentation Inc. -- Level and Pressure measurement systems.

What you will see and learn about:

Throughout the tour, you will see various production lines that utilize the concepts of Lean manufacturing and many Continuous Improvement initiatives that have been done such as:

• batch reduction (one piece flow) and workplace layout

• 5S

• CIP boards

• Kaizen

• Kanban

• Pull System

• Visual Controls

• TPM

Note:

• Casual attire

• Closed-toe shoes required

********** SPACE IS LIMITED **********

Monday, April 23
1:00 pm - 4:00 pm
*2007 IW Best Plant Winner

General Cable, Indianapolis Compounds, a state-of-the-art ISO 9001:2000 certified compounding facility, is dedicated to the production of compounds at quality levels that set the standard for the industry. Specializing in advanced polymer research, Indianapolis Compounds has an established reputation for manufacturing innovative compounds that set the standard for purity, dispersion and performance. An unrelenting commitment to innovation makes Indianapolis Compounds a leader in the development of commercialized, high-performance, ultra-clean filled EPDM insulation and semi-conductive shield compounds for low-, medium- and high-voltage cables, and Industrial and Specialty Cables.

What you will see and learn about:

• A highly automated plant that uses two continuous operation Buss Ko-Kneaders (140mm) and one 200mm Buss Ko-Kneader, a Farrel F-80 Banbury mixer, and ten class 10,000 clean rooms

• Central control room from where one operator can monitor the entire plant operation

• Lean and Continuous Improvement methods such as:

  • Kanban

  • Pull System

  • 5s

  • OLPC

  • Lean Sigma teams

  • Visual Factory

Note:

• Casual attire

• No shorts or open-toed shoes allowed

• Safety shoes, safety glasses, and hearing protection are required when touring the plant.

Monday, April 23
7:45 am - 1:15 pm

As the first continuous thin-slab cast flat-rolled steel making facility in the world, the Crawfordsville, Indiana mill puts its extra experience into everything it makes. With an annual capacity of 2,200,000 tons of hot-rolled, cold-rolled and galvanized products, it serve a broad range of customers including service centers/processors, pipe and tube, construction, agricultural, electrical and others. The continuous thin-slab cast flat-rolled steel making process transforms molten metal into hot band in uninterrupted operation. The pickling and cold-rolling operations have an annual capacity of 1.5 million and 1 million respectively. They have one of the most cost-effective galvanizing lines in the country, with an annual capacity of 375,000 tons.

Note:

• Long pants (preferably jeans) should be worn.

• Hard sole shoes that cover the entire foot are required

• Hard hats, safety glasses and ear plugs will be provided by Nucor.

Monday, April 23
7:45 am - 1:00 pm OR 11:45 am - 5:00 pm

Subaru of Indiana Automotive, Inc. (SIA), a subsidiary of Fuji Heavy Industries, Ltd., is the home of North American Subaru production. Models built at the plant include the Subaru Legacy, Outback and Tribeca. In 2007, SIA also began producing the Toyota Camry under contract with Toyota.

SIA was the first auto assembly plant in America to achieve zero landfill status, to be ISO9000 and ISO14001 certified, and to be designated a Backyard Wildlife Habitat by the National Wildlife Federation. The plant has also been awarded the Gold Achievement Award from the Environmental Protection Agency.

What you will see and learn about:

• The tour will take guests through the Stamping Shop, the Body Shop and Trim, and Final. Guests will also get a glimpse of the Paint Shop and learn about the Engine Shop.

• SIA Associates specializing in TPM and Environmental Compliance will provide an overview of SIA's TPM and Kaizen activities, processes and successes.

• Throughout the plant, examples of TPM and Kaizen will be highlighted

• A question and answer session following the tour will allow ample time for guests to learn more about SIA's Continuous Improvement initiatives

Note:

• It is a 1.5 hour walking tour that traverses a catwalk and includes several sets of stairs. Individuals who are not able to walk long distances, up stairs or have issues with heights should not take the walking tour. If you have special needs, please notify conference management at least 2 weeks in advance to arrange for special assistance at the plant.

• No high-heeled or open-toed shoes are allowed

• No tank tops or sleeveless shirts are allowed

• No electrical devices (including cameras and cell phones) will be allowed in the plant; these must be left on the bus or with the plant's Lobby Receptionist during the tour

****** PLANT TOUR IS FULL ******

Monday, April 23
8:45 am - 1:15 pm OR 12:00 pm - 4:15 pm
*2011 IW Best Plant Winner

Built on a reputation for excellence, Toyota is known for its quality, reliability and durability. Quality is the hallmark of the Toyota Production System (TPS) practiced at all Toyota manufacturing facilities, including Toyota Industrial Equipment Manufacturing (TIEM), a zero-landfill facility in Columbus, Ind.

The first lift truck rolled off the line at TIEM in 1990. Since then, the plant has grown six-fold from its initial employment to nearly 800 TIEM associates, increased production more than 10-fold and tripled in physical size.

What you will see and learn about:

• Toyota's world-renowned Toyota Production System. The TPS is world famous for maintaining the highest standards of quality and efficiency and is built on Toyota's famous "just-in-time" production system. Just-in-time aims to smooth the work flow, reduce inventories and lower production costs.

• A facility that manufacturers in excess of 90 lift trucks per day in a one-shift operation, with quality built in every step.

Note:

• Closed-toe shoes are required

• Competitors of Toyota Industrial Equipment Manufacturing or Toyota Material Handling U.S.A., Inc. will not be permitted.

• No cameras or video equipment allowed

Monday, April 23
7:00 am - 12:30 pm

Established in 1985, Wabash National Corporation (NYSE: WNC) is a leading manufacturer of transportation and industrial products. Headquartered in Lafayette, Ind., the company and its subsidiaries specialize in design, production and distribution of transportation products including dry freight vans, refrigerated freight vans, platform trailers, and intermodal equipment. In 2008, the company began to diversify into new markets and now manufactures frac tanks for the energy and environmental services markets, and composite panels and related products for use in a variety of industrial markets.

Products manufactured in Lafayette include: DuraPlate®, DuraPlate HD® and FreightPro dry freight vans; ArcticLite® refrigerated freight vans; DuraPlate composite panels; portable storage containers; and frac tanks.

What you will see and learn about:

During a tour of Wabash National, attendees will learn more about the company's "Lafayette Transformation" initiative designed to improve build consistency and process yield, reduce costs and open floor space for new business opportunities. The Lafayette Transformation initiative included the consolidation of six assembly lines into three, as well as consolidation of ten material storage locations into one. Attendees will gain exposure to Lean, 5S and Continuous Improvement practices in action including:

• Consolidation

• Standardization

• Quality Control

• Inventory Management

• Process Control

• Kanban

• Communication: Visual Controls, Training

• Kitting

Note:

• Closed-toe shoes with no heels must be worn (if you have steel-toed shoes, please wear them; otherwise slip-ons will be provided)

• Long pants and long-sleeved shirts are required

• No cameras or video equipment are allowed