Mercedes Benz, U.S International, Inc. (MBUSI) | Tuscaloosa, Alabama
Company Information:
Since 1997, MBUSI has produced the new M-class sport utility vehicle in its new Greenfield plant in Vance, Alabama. During two shifts, 700 employees assemble 180-200 high quality SUVs per shift (one every three minutes).
Situation:
MBUSI has adopted best practices from the auto industry worldwide. The MBUSI Production System is based primarily on the principles and techniques of lean manufacturing. All MBUSI employees are trained on lean tools in the new on-site Mercedes Training Institute operated by Alabama Industrial Development Training (AIDT). MBUSI requested the ATN-UAH Lean Factory Simulation from AIDT.
The training needs extended beyond MBUSI. After Daimler-Benz merged with Chrysler Corporation, a cross-functional multi-plant team of German managers was tasked to develop a new DaimlerChrysler, AG Operating Model. MBUSI helped pilot a four-day training program on the new operating model. The team was looking for a training approach that integrated the model’s five major elements that focused on work standardization and JIT, and that could energize all types of employees.
Center Assistance:
Having helped NIST-MEP develop the Lean 101 simulation, ATN-UAH had two experienced and certified Lean 101 trainers. During four rounds, Lean 101 participants experienced the transition from traditional, chaotic push manufacturing to the lean, one-piece flow, cellular and pull system. After meeting with MBUSI and AIDT, ATN-UAH added material and training activities to simulate just-in-time delivery of parts sequenced to the orders being built. They also trained 18 MBUSI managers in a pilot seminar. The following month, DaimlerChrysler Stuttgart piloted the ATN-UAH Lean Sequential Just-In-Time (SJIT) Simulation as one day of the pilot training program at MBUSI for 16 members of the DaimlerChrysler Integration Team. ATN-UAH has since trained two more groups of team leaders at MBUSI.
Results:
The eight-hour Lean SJIT simulation helped many of the participants experience the total system that MBUSI has implemented. Through continuous role-playing that presents cultural issues and management implications, it exceeded the expectations of all participants. The DaimlerChrysler Team has included the ATN-UAH Lean SJIT Simulation in its final training program for the new Operating Model.
Client Comments:
“Mercedes Benz at Vance, AL is pleased to work with the ATN and UAH. Their lean simulation is the best we have seen. ATN-UAH and the MEP really improved the original lean manufacturing simulation. In particular, the outstanding role playing by the instructors helps to demonstrate the cultural and management transitions that occur with adoption of lean thinking. The value of this simulation (and others) is that you can learn more about the general by studying the specific than you can learn about the specific by studying the general (the traditional approach).” – Mike Kinney and Christoph Disch, MBUSI
“This was the best training! It demonstrated all five elements of the new DaimlerChrysler Operating Model.” – Michael Thomas, Team Leader and Paul Starker, DC-AG
“Excellent training! You got a very unusual reaction. We are usually very reserved. The group’s applause at the end of the day was a big compliment to the ATN-UAH Lean 101 team.” – Manfred Ziegler, DC-AG