Pros: free lunch
Cons: unsafe city
At the end of my three hour plant tour, I went home and cried. That month, I let go the Quality, Production and Materials manager and decided to start from scratch. Implemented the Toyota Manufacturing System (demand knowledge, sales and inventory systems, MPS, MRP, culture, waste, standards, 5S and Metrics) at all levels and on every Wire-Harness assembly board. Little by little you could see the puzzle taking shape to the point where we could actually implement tack-time and material synchronization on every assembly board at their finest. Finally, after so many years, a place where all the lean manufacturing techniques came reality! Customers were also very happy with our results, to the point where our sales people brought more business and gave plant tours.