AboutJoe Martin Expertise I can answer questions about Quality Systems (AS9100, AS9103, Boeing D6-82479, etc.) Particular areas of expertise are Statistical Process Control (SPC), sampling inspection, design for Six Sigma, and Six Sigma tools in general.
Experience Quality engineer in aerospace for 20+ years. ASQ Certified Quality Engineer (#8920) since 1982.
Expert: Joe Martin Date: 7/19/2007 Subject: Rail Transportation
Question Hello Mr Joe Martin,
I am an analyst with a business research firm and right now working on a report on Global Rail Transportation Industry. Regarding that I would like your help on certain questions.
- Most of the big rolling stock manufacturer's like Bombardier are said to have implemented 'Just in Time' and 'Lean Manufacturing' concepts throughout there plants. I would like to know your opinion on how much is it successful and also if possible extent of the implementtation of these techniques?
It would great to have opinions from an expert like you.
Looking forward to your reply at the earliest
Thanks and Regards
Ajay Biswari
Answer Ajay--
Interesting question! Unfortunately, I have no direct knowledge of the rail industry. If (I haven't checked) GE still manufactures locomotives, I would assume they've implemented--or tried to implement--"Six Sigma" and all the other "initiatives" for which GE has become known. You might try to get some information directly from GE.
If you are not familiar with some of the more popular textbooks on Lean and JIT, scanning them would be time well spent. Frankly, I am no longer current in such things, so I can't recommend specific titles.
My experience with "JIT" in aerospace is that's it's largely a myth. The prime contractors are simply forcing the subs to hold all the inventory--in addition to agreeing to accept payment as much as 90 or 120 days after invoice!
The aerospace primes are notoriously poor at making and sticking to schedule, often resulting in a mad scramble to magically create parts for which the realistic lead time has already evaporated. This may improve with projects such as the Boeing 787, but I remain skeptical until it happens.
On the positive side, I have seen some evidence of success with Lean MFG, particularly in small cells with more-or-less continuous production of the same or similar items (pneumatic valves, for example.) Whether or not this has been, or can be, translated to an aircraft or locomotive/rolling stock production line, I don't know.
In my opinion--and it's that and nothing more--almost all "initiatives" such as JIT, Lean, and Six Sigma are way overblown. CAN they work? Yes. But there's always considerable "hype" involved, and the results are difficult to objectively quantify. (Ever seen or heard of a single instance where failure was admitted?)
To really answer your question, you'd need to make yourself somewhat of an expert, at least from the academic perspective, then actually visit a plant or two to judge for yourself.
