Volume 8 No. 12            December 2007            www.superfactory.com
 
 In This Issue

  • From the Editor
  • Manufacturing Excellence News
  • In the Blog
  • Upcoming Events
  • Featured Book - Accounting for World Class Operations
  • Article - Lean Accounting - Beyond the Back Office
  • Featured Blog Post - Boeing's Outsourcing Hell
 
 From the Editor

This month sees the first in a series of articles on lean accounting by Brian Maskell and his team at BMA Inc. Over the next several months he'll help us dive into several of the theoretical and implementation aspects of lean accounting.

AME has provided to us over 30 promotional posters for their 2008 Conference in Toronto. These posters can be downloaded at no cost, with resolution supporting up to 30"x38" sizes. Try a lean-oriented poster instead of the traditional ones on your walls! See all posters here.

Superfactory has launched a new Jobs Board, which already has over 200 lean-oriented jobs. Take a look at the available jobs, or post your own openings for a $10 fee (the minimum amount allowed by the system, to avoid spam jobs) to access about 5,000 lean-oriented Superfactory visitors per day. Visit the Superfactory Jobs Board.

As always we appreciate your support for our mission to spread manufacturing excellence knowledge. Click here for more information on sponsorships.

- Kevin Meyer

 
 Manufacturing Excellence News
 
 In the Blog

Join the other 3,000 readers who get their daily dose of blunt manufacturing reality by subscribing to the Evolving Excellence blog!

Recent posts in the Evolving Excellence blog include:

  • Boeing's Outsourcing Hell - Boeing grapples with the effects of outsourcing not only production, but also design.
  • Poll Update - Ongoing results from our polls of the best lean companies, best presidential candidate for manufacturing, and most important manufacturing policy issue.
  • Karoshi - The phenomenom of death from overwork haunts Toyota.
  • Chery Learns - Chinese automaker Chery is pulling out all the stops to learn about world class manufacturing.
  • Yes, U.S. Manufacturing Can Compete - Examples abound of companies competing globally from U.S. factories.
  • Toyota Raises the Tide - Local manufacturers are worried about the new Toyota plant in Mississippi, but they shouldn't be.
  • Various Angles on Chinese Aircraft - Several major aircraft manufacturers are setting up shop in China, sometimes partnering with future competitors.
  • Lean Approach to Email Management - Hint: it doesn't involve new technology.
  • Lean is Not a Metric - The fallacy of focusing on singular metrics of "leanness. "
 
 Upcoming Events

Visit the Superfactory Events Calendar for the full list of events.

10 Dec Certified Lean Master - Hoffman Estates, IL - Transformance Advisors - www.transformanceadvisors.com
10 Dec Quality & Enviro Auditing - Dallas, TX - High Tech Seminars - www.hightechnologyseminars.com
10 Dec Lean Tool Awareness - Columbus, OH - Productivity Inc. - www.productivityinc.com
10 Dec Lean Manager Certification - Columbus, OH - Productivity Inc. - www.productivityinc.com
10 Dec Lean Experience - Novi, MI - Lean Learning Center - www.leanlearningcenter.com
11 Dec Leadership 101 - Mason, OH - MMS - www.mmsresults.com
11 Dec Creating a Lean Culture at Steelcase - Kentwood, MI - AME - www.ame.org
12 Dec Leadership in Lean Equipment - Dayton, OH - University of Dayton - www.competitivechange.com
13 Dec Lean Mfg Simulation - Mason, OH - MMS - www.mmsresults.com
13 Dec Pioneering Approach to Workculture Change - Juncos, PR - AME - www.ame.org
14 Dec Lean Enterprises: Maximizing Value - Kansas City, MO - Transformance Advisors - www.transformanceadvisors.com
18 Dec Intro to Lean / Lean 102 - Mason, OH - MMS - www.mmsresults.com
4 Jan The Lean Experience - Novi, MI - Lean Learning Center - www.leanlearningcenter.com
4 Jan Lean Enterprise Overview - New Britain, CT - Leanovations - www.leanovations.com
14 Jan Total Productive Maintenance Workshop - Paragould, AR - AME - www.ame.org
17 Jan Batesville Casket Continuous Improvement Journey - Manchester. TN - AME - www.ame.org
24 Jan PDCA in Action - Boise, ID - AME - www.ame.org
28 Jan 9th Annual Six Sigma Summit - Orlando, FL - IQPC - www.iqpc.com
 
 Featured Book

  Accounting for World Class Operations
  by Jerry Solomon & Rosemary Fullerton

 

Firms need performance measurements that reflect the benefits of change made from implementing Lean practices. Too often those benefits are hidden in outdated accounting reports filled with indecipherable, archaic jargon. The need for a clearer, simpler, more strategic performance measurement system in Lean companies is long past due. Solomon and Fullerton present that roadmap in their unique and timely book. Their clear and concise writing take the mystery and fear out of a Lean accounting conversion and their case examples from real-world experiences of successful accounting changes that support Lean conversions are insightful for those wanting reassurance and direction.

More Information

 
 Article

MalcolmLean Accounting - Beyond the Back Office
by Brian Maskell and the BMA Inc. Team

 

This article is the first in a series about lean accounting methods. The series will be based on the newest book, published in October 2007, The Lean Business Management System; Lean Accounting Principles & Practices Toolkit.

In our practice at BMA Inc., when we first introduce lean accounting to companies, questions always arise, something along the lines of: “Well, that all makes sense, but how do you do it?” or “How do you get this past your auditors?” or “Is this really GAAP compliant?” and the like. This series of articles will examine details or “how to’s” of this evolving discipline and show you how to put it to work in your company as a business management system that supports your lean manufacturing efforts seamlessly.

The first national Lean Accounting Summit conference opened its doors in Dearborn, MI in September 2005. The day before the conference began, a group of people with lean accounting knowledge and experience came together . Their purpose: to discuss lean accounting issues and to share their ideas and vision.

This group concluded that while there was generally good understanding of the problems, there was not widespread understanding of the solutions. What was needed was a comprehensive framework that would pull together the principles of lean accounting with the practices that support them and the tools and methods that lean companies can apply to the task. After three months of work, the team of lean learning leaders was able to define the principles, practices, and tools that comprise the “state of the art” as it exists, and to chart a path for how it needs to evolve in accordance with a comprehensive lean vision.

Read entire article

 
 Featured Evolving Excellence Blog Post

Boeing's Outsourcing Hell

A year ago we began to question the rationale of the supply chain convolution Boeing was creating for the 787 Dreamliner, and we've chronicled the problems since then.  From having to design and build huge Rube Goldberg transportation devices, miscalculating total assembly time, transferring knowledge to a potential competitor, running out of fasteners, and even spinning off a subassembly operation that turned into a profitable company... something just didn't pass muster.  Sure there are a lot of political aspects to their selling activities, and the design and technology of the Dreamlifter is extraordinary... but was it worth it?

Last month, Mike Bair, former 787 boss, gave a rather remarkable speech where he confronted many of the problems.

Mike Bair, former 787 boss, gave a pretty blunt talk about 787 suppliers on Wednesday to a group in Everett. "Some of these guys we won't use again,'' Bair said.

If he had to do it over again?

For Boeing's next all-new jet program after the 787, Bair said, it would be better to have a central manufacturing site rather than the global assembly method that is being used for the 787. He said Boeing would put pressure on its suppliers the next time to locate in the same area.

Yes, Bair somehow remains a Boeing employee.  Time will tell if he's right, but Friday's Wall Street Journal brought Boeing's supply issues to the forefront.  Pardon me if I gloat a bit, although I really wish I didn't have to, but we predicted that out a year ago.

On Tuesday, Boeing Co. will give Wall Street a progress report on its 787 Dreamliner, as it scrambles to overcome a six-month delay in producing the new jet. A look inside the project reveals that the mess stems from one of its main selling points to investors -- global outsourcing.

And a major part of the problem is not just the assembly from parts built around the world, but the actual design.

Read entire post (you can also view and post comments)

The Superfactory Newsletter is published monthly to over 50,000 subscribers worldwide.

Sponsors & Events

Sponsorship Information


Inside Superfactory

About
Articles
Blog
Books
Events Calendar
Glossary
History of Excellence
Virtual Factory Tours
Lean Jobs Board


Online Learning

Lean Overview
5S & Visual
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke
Production Preparation
Pull/JIT/Kanban
Quick Changeover
Standard Work
Theory of Constraints
TPM
Value Streams


PowerPoint Presentations

Lean Manufacturing
5S and Visual Controls
Kaizen
Value Streams
Pull, JIT, Kanban
Poka Yoke
Mistake Proofing
Quick Changeover
Cellular Manufacturing
Activity Based Costing
Theory of Constraints
Total Productive Maint
Balanced Scorecard
Knowledge Management
E-Commerce
Job Design & Labor Stds
Human Factors
Outsourcing Strategies
Cost Accounting
Supply Chain Strategies
Capital Budgeting
Facility Strategies
Technology Assess
Strategic Management
Forecasting & Planning
Project Management
Lean Office Overview
Office 5S
Office Kaizen
Office Value Streams
Office Pull, JIT, Kanban
Office Mistake Proofing
Office Cells
Activity Based Costing
Office TQM
Office TOC
Total Quality Mgnt
ISO 9001:2000
Root Cause Analysis
Six Sigma
Failure Modes & Effects
SPC
Design of Experiments
New Product Dev

Factory Toolbox

Lean Toolkit
Quality Toolkit
Materials Toolkit
Procedures Toolkit
Engineering Toolkit
Tools & Forms Toolkit
ESD Toolkit
Biosafety Toolkit
HR Toolkit
Marketing Toolkit
Safety Toolkit


Partners


GlobalSpec


BizManualz


Automated Learning


Enna

© 2007 Superfactory Ventures LLC. All rights reserved.