Exposing the Hidden Factory Within
The factory that erodes profits and destroys manufacturing
Presentation Code: VS1-02
Value Stream: VS1 - People
Day & Time: Tuesday, Oct 25, 2011 - 10:30 AM
Length: 1 hour, 10 minutes
There is often a Hidden Factory Within: a silent killer that can destroy your business. The Goodyear Fayetteville plant had been struggling to survive in the global economy, and for years the plant had added labor to meet volume demand whenever it saw poor performance. But in today's economy, this meant Fayetteville was unable to compete with foreign and even domestic competitors. Morale was low and motivation to improve was dormant. It was a silent killer.
By building trust, being straightforward at a person-to-person level when communicating expectations and rewarding and recognizing individual contributions, the Fayetteville leadership team drove plant output from 31,200 to 38,000 tires per day in 6 months, all while reducing costs. The additional 6,800 tires per day contributed substantial gains to the plant's bottom line. The plant had turned around its hidden factory.
In this presentation:
- Learn how Fayetteville's Goodyear plant discovered its hidden factory.
- Find out why Fayetteville's Goodyear plant called this Hidden Factory: "The Silent Killer."
- Lean how this Fayetteville's plant turned its Hidden Factory into an asset.
- Find out how the Fayetteville plant built trust and used visual tools to turn around the Hidden Factory.
- See how the Fayetteville plant learned to communicate in ways that brought bottom line results in weeks, not years.
- Witness how investing in morale and engagement brought huge bottom line profits.
- Hear how you can align your organization to expose and turn around your Hidden Factory.
The Global Footprint:
Goodyear is the No. 1 tire maker in North America and Latin America. Goodyear employs approximately 72,000 people around the world. Goodyear is one of the world's largest tire companies, with operations in most regions of the world. Together with its subsidiaries and joint ventures, Goodyear develops markets and sells tires for most applications. Goodyear operates 56 plants in 22 countries. In 2010, Goodyear posted net sales of $18.8 billion.
Become a market-focused tire company providing superior products and services to end-users and to our channel partners, leading to superior returns for our shareholders.
Aerial ambassadors of our company since 1925, Goodyear operates three blimps in North America. In the United States, they are based in Akron, Ohio; Carson, California, and Pompano Beach, Florida.
Billy Taylor, Plant Manager
Billy Taylor is Plant Manager at Goodyear's Fayetteville tire plant, which has 3,000 associates and produces 38,000 consumer tires per day. Billy is known for his ability to motivate others. He has a strong vision for business excellence and a better community, and a track record of building successful high performance teams. Billy embraces people holistically as the base for a true Lean culture.
Prior to being named plant manager at Fayetteville in June 2010, Billy served in management positions at Goodyear facilities in Freeport, Ill.; Kingman, Ariz.; Topeka, Kan.; Tyler, Texas; and Lawton, Oklahoma.
In 2010, Billy was recognized as one of the most admired executives with a public company with less than $500 million in annual revenue. Billy was also recognized by The Journal Record, the Oklahoma City-based business newspaper affiliated with Dolan Media Company.
Billy holds a Bachelor of Science degree in Electrical Engineering from Prairie View A&M University and an MBA from Baker University.
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