Plant Tours
Acuity Brands Lighting (June 15, 2006)
On June 15, 2006, the APICS Chapter of Central GA attended
a plant tour hosted by the GA Production Facility of Acuity Brands Lighting,
formerly known as Lithonia Lighting, in Cochran GA. There were 32 members and
associates present for the tour. Jim Rush CPIM Acuity Brands Lighting began the
tour with a presentation of the plant's history and how they have adjusted their
manufacturing philosophies and techniques to adapt to changes in their industry.
A few years ago, Acuity Brands Lighting had many
manufacturing facilities across North America, and saw the need to consolidate
their operations into a few strategic locations. The Cochran Plant was one of
the sites selected to remain as a primary manufacturing facility. During this
reorganization, new products were introduced to the Cochran facility, but the
high manufacturing costs associated with this facility caused the executive
management team at Acuity Brands to question the practicality of these product
transfers.
In 2002, Acuity Brands CEO, Vern Nagel, introduced
LEAN-manufacturing concepts to the various manufacturing facilities, with the
support of Lean Horizons Consulting firm. As Lean Manufacturing was implemented,
the Cochran facility began a transformation that has enabled them to compete
with the manufacturing costs of facilities located in Mexico and China.
After the presentation, we were shown how cellular work
centers are used to improve quality, reduce cost, and improve productivity.
These work cells are designed for quick, convenient production. We also saw how
standard worksheets are used to simplify the production process. Kan Ban
inventory systems are utilized throughout their operation to improve product
flow, reduce inventory cost, and improve delivery time. Acuity Brands takes
advantage of benefits provided by vendor managed inventory systems. They have
also made arrangements with many of their suppliers to replenish material
inventories through the KanBan systems.
Acuity Brands has implemented a 5S program to improve shop
floor organization. The benefits of this program are visible throughout the
plant. A state-of-the-art lighting system has been installed to improve
visibility, and improve quality in the workmanship of their employees. There are
still many construction projects underway, as Acuity continues to improve their
operation.
The Cochran Acuity Brands Lighting is a modern day
manufacturing success story, and a testament to the benefits of the Toyota
Production Model.
After the tour, Jim Rush CPIM reminded all in attendance of
the importance, and gave a few tips for maintaining a record of recertification
activities to all CPIMs. Afterward, Dennis Leahy CPIM was presented with an
award by the chapter for Instructor of the Year.
The plant tour was a huge success. The APICS Chapter of
Central GA is very grateful to Acuity Brands Lighting for providing this tour,
and the support they continue to provide to our chapter.
Keith Flury
June 26, 2006
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