Rx for manufacturing quality: Shingo winner looks to continuous improvement. (Medical Manufacturing).Strict adherence to its Quality Leadership Process helped Baxter Healthcare's North Cove plant in Marion, NC, capture the coveted cov·et
v. cov·et·ed, cov·et·ing, cov·ets
1. To feel blameworthy desire for (that which is another's). See Synonyms at envy.
2. To wish for longingly. See Synonyms at desire. Shingo Prize for manufacturing excellence last year.
Several achievements contributed to Baxter receiving the award--a lead time reduction of 84 percent, first-pass yields at 99.65 percent; on-time delivery rate above 99 percent; energy requirements reduced by 51 percent; work-in-process inventory turns in excess of 170; and a pipeline inventory reduction of 36 percent.
Founded in 1931, Baxter Healthcare was the first manufacturer of commercially prepared intravenous solutions. The company, with its headquarters in Deerfield, IL, serves healthcare providers and patients in 100 countries. Baxter is known for several firsts in the healthcare industry including the first commercially manufactured intravenous (IV) solutions, the first artificial kidney artificial kidney: see kidney, artificial. , and the first concentrated clotting factor clot·ting factor
Any of various plasma components involved in the clotting of blood, including fibrinogen, prothrombin, thromboplastin, and calcium ion. Also called coagulation factor. to treat hemophilia.
The North Cove facility has been situated in the foothills of the Blue Ridge mountains Blue Ridge also Blue Ridge Mountains
A range of the Appalachian Mountains extending from southern Pennsylvania to northern Georgia. It rises to 2,038.6 m (6,684 ft) at Mount Mitchell in the Black Mountains of western North Carolina. since 1972. The 1.4 million square-foot plant manufactures IV solutions and peritoneal dialysis peritoneal dialysis
The removal of soluble substances and water from the body by transfer across the peritoneum, utilizing a solution which is intermittently introduced into and removed from the peritoneal cavity. (PD) solutions for home kidney dialysis Dialysis, Kidney Definition
Dialysis treatment replaces the function of the kidneys, which normally serve as the body's natural filtration system. . The 2,500 employees help produce more than one million containers of IV solutions each day. The North Cove facility has been ISO (1) See ISO speed.
(2) (International Organization for Standardization, Geneva, Switzerland, www.iso.ch) An organization that sets international standards, founded in 1946. The U.S. member body is ANSI. 9000 certified since 1994
Eye on the prize
The Quality Leadership Process (QLP QLP Quebec Liberal Party (Canada)
QLP Quality Leadership Profile (leadership survey for use in the tertiary sector)
QLP Query Language Processor
QLP Quarter-Life Productions ), a continuous improvement management process, was instituted at the North Cove facility in 1985. It establishes the foundation for providing quality products and services to customers, says Phil Batchelor, plant manager at Baxter. The QLP includes eight deployment strategies.
1) Customer responsiveness and growth-generating customer knowledge and responding to requirements which will help grow customer loyalty and new business.
2) Quality operating system-gaining knowledge, predictability, training and the assurance to continually raise quality standards.
3) Value improvement program--managing projects and improving costs and quality.
4) Supply chain management--managing relationships with suppliers and customers. Improving speed, while managing costs.
5) Leadership/ownership -- motivating employees through involvement, training, tools and the appropriate environment. Maximizing employees' potential, and at the same time recognizing them as individuals.
6) Public responsibility -- becoming partners with the community through service projects and other efforts.
7) Information management -- generating an information system to manage processes that will enable more timely and accurate decisions.
8) Equipment effectiveness--getting people more involved and encouraging them to take ownership of the equipment which in turn improves the reliability of the equipment.
"The deployment strategies have grown from two or three to eight," Batchelor says. "They are dynamic, meaning they change on an ongoing basis. We are in the process of reviewing them now. This foundation is the reason behind us receiving the Shingo Prize."
The QLP was based on an integration of quality management and lean manufacturing Lean manufacturing is the production of goods using less of everything compared to mass production: less human effort, less manufacturing space, less investment in tools, and less engineering time to develop a new product. systems. Batchelor says the total quality management system and deployment principles were born from this integration.
Baxter also uses state-of-the-art instrumentation including micrometers, comparators and vision inspection equipment to insure quality.
"In the pharmaceutical industry, we make sure that our processes and products are validated and monitored," Batchelor says. With this in mind, the deployment strategies take the product from the research and development stage, through the facility to the customer.
Established in 1988 to promote world-class manufacturing, the 2000 Shingo prize for excellence in manufacturing The Shingo Prize for Excellence in Manufacturing is awarded annually to by Utah State University to North American companies that "achieve world-class manufacturing status." It was established in 1988 and is named in honor of Shigeo Shingo. External links
Lockheed Martin (NYSE: LMT) is a leading multinational aerospace manufacturer and advanced technology company formed in 1995 by the merger of Lockheed Corporation with Martin Marietta. , Fort Worth, TX; and Lucent Technologies, Mt. Olive, NJ. The College of Business, Utah State University Utah State University, mainly at Logan; coeducational; land-grant and state supported; chartered 1888, opened 1890. It publishes Utah Science, Western Historical Quarterly, and Western American Literary Journal. and the National Association of Manufacturers administer the prize.
Stephanie J. Fellenstein is editor of Quality in Manufacturing magazine, also published by Adams Business Media.
RELATED ARTICLE: The man behind the prize
Born in 1909 in Japan, Shigeo Shingo was impressed early on by the idea of streamlining processes to eliminate waste.
He wanted to teach the world to see manufacturing processes rather than separate operations. Before production management could be improved, Shingo said two things had to be understood clearly: 1) what a production management system is and 2) how to carry out improvements.
The Shingo prize was established in 1988, two years before he died. Utah State University awards the prize annually.
The aim of the Shingo Prize is to facilitate an increased awareness in the manufacturing community of excellent to world-class manufacturing practices and techniques. The prize also fosters understanding and collaboration of successful methodologies, and encourages research in business and manufacturing processes.
Manufacturers in the United States United States, officially United States of America, republic (2005 est. pop. 295,734,000), 3,539,227 sq mi (9,166,598 sq km), North America. The United States is the world's third largest country in population and the fourth largest country in area. , Canada and Mexico, and researchers throughout the world are eligible.
The award recognizes manufacturing companies, divisions, and plants who demonstrate excellence in manufacturing leading to superior customer satisfaction and business performance. It also awards research and writing that addresses innovative methods, systems and processes that follow the Shingo prize's achievement criteria.
Shigeo Shingo, The Shin go Production Management System. Improving process functions. (Productivity Press, Cambridge, MA. 1992)
Shingo prize web site: http://www.shingoprize.com
Baxter Healthcare, IV Systems Division, North Cove facility, Marion, NC. or http://www.OneRS.net/105tp-359 or circle 359.