Focused solely on implementation for electronics manufacturing and featuring actual case studies from industry leaders, the IPC Lean Sigma Conference for Electronics Manufacturing will offer insight into ways to immediately implement Lean Sigma methodology and reduce cycle times, inventory levels, and costs while improving quality.

The technical conference is a must-attend event. Topics include: Lean Design of Experiments (DOE), a method used to identify the ideal combination of process variables to achieve desired quality; the Kaizen model of team training to maximize the waste-reduction benefits of Lean; Value Stream Mapping to analyze the flow of materials and information to find ways to increase efficiency of lead time; and an introduction to 5S, a process to organize, clean and standardize the workplace. Come network with some of the brightest and best people applying Lean Sigma technology to their workplaces including: Intel, Merix, Celestica, Plexus, Tyco Electronics, Kyzen, Panasonic, Enthone and Diversified Systems.

The workshops will cover the fundamental concepts of Lean Sigma presented by some of the industry’s foremost experts.  Ronald C. Lasky, Ph.D., senior technologist at Indium Corporation of America; Rita Mohanty, Ph.D., director of advanced development at Speedline Technologies, Inc.; and Tim King, senior partner with the Tupelo Group, LLC, will share their expertise and real-world experiences.

This event will benefit all operations managers, including manufacturing, field application, market development and inventory control engineers.

Tuesday, November 17, 2009 — Fundamentals of Lean Sigma Workshop

Value Stream Mapping and 5S Workshop (8:00 am–12:00 pm)

Tim King, Tupelo Group and Dr. Ron Lasky Indium/Dartmouth College

Lean Sigma is a rigorous, data-driven, results-orientated approach to process improvement. It combines two of the most powerful management methodologies that have evolved over the last decade. Lean — the concept of driving speed and cost and Six Sigma — the concept that drives quality and reliability. At the heart of Lean Sigma is Value Stream Mapping. Value Stream Mapping focuses on optimizing the process and removing nonvalue-added steps. In the first part of the workshop, you will learn the methodology used in value stream mapping, including the tools required for evaluating, charting and determining the most efficient process. In the second part, students will learn and understand the 5S methodologies of simplification. Students will learn from examples that can be applied immediately to optimizing engineering and business processes.

Lean DOE and Kaizen Event Workshop (1:00 pm–5:00 pm)

Dr. Rita Mohanty, Speedline Technology

Lean Sigma is used to make improvements inside a company’s internal operations. These improvements range from supply chain management to new product design. One of the keys to knowing what to measure is the use of design of experiments (DOE). Dr. Mohanty will lay the foundation for basic DOE and relate how basic DOE can lead to optimization of any process. Often results of DOE’s lead to additional Kaizen events. Attendees of this workshop will gain a basic understanding of DOE and learn how to use outcomes to engage in Kaizen events.  Dr. Mohanty has been a lean change agent within the electronics industry.

Lean Sigma — Pathway to Manufacturing Excellence — Aaron Spearin, a Master Black Belt at Enthone, provides insights from the manufacturing perspective. Over the past decade, Aaron has implemented lean in automotive, aerospace and photovoltaic market segments. He lays the a solid foundation for the rest of the conference.

Value Stream Mapping for Supply Chain Management Case Study — Doris Chu is the materials lean initiatives manager at Intel Corp. Her case study illustrates how value stream mapping can improve operational efficiency and build long-standing relationships with suppliers.

A3 Thinking in Combination with Kaizen — Results in Better Inventory Management — Alex Thomason is the director of lean and six sigma at Merix. Alex will present how A3 Thinking can create a Kaizen Planning Process based on the Plan-Do-Check-Act cycle. The results of the process provide insights on how to optimize inventory management. Faster inventory cycle times result in better bottom-line performance.

Optimizing Manufacturing Operations — Rodger Diehl's 32 years experience in manufacturing and field service with AMP (Tyco Electronics) contributes to his unique insight into lean. He provides information on software tools that can help optimize operations.

Kaizen Event Case Studies — Implemented for Process Improvement — Robert Atkinson is a leader of Lean Sigma activities at Celestica. He will present on three Kaizen events conducted at Celestica which led to greater efficiencies in electronics manufacturing operations, reducing cost and streamlining operations.

How SMT Equipment Vendors are Delivering Lean Solutions to Improve OEE & Profitability —
States Mead is a senior solutions consultant at Panasonic Factory Solutions Company of America with extensive experience and management skills in lean manufacturing operations. States will discuss how of Lean Sigma methods were used to optimize placement operations for surface mount placement equipment.

Using Lean Sigma Methodology for Selecting Best-Fit Cleaning Agents for Electronics Assemblies — Rich Brooks is a staff engineer with Kyzen who has extensive experience in Six Sigma and Lean methodologies. His case study will demonstrate how lean methods can be applied to selection of cleaning materials used in de-fluxing assemblies.

Key Element in Lean Implementation — Culture Change — Jonathan Bailey has seen firsthand what happens when companies are not aggressive enough when implementing lean. Jon shares a case study at Continental that highlights the need to become fully engaged in lean sigma and embrace the culture change that is required across the entire organization.

Lean DOE — Dr. Ron Lasky is an instructional professor, Thayer School of Engineering, Dartmouth College, a senior technologist at Indium Corporation of America and a Six Sigma Master Black Belt Instructor. He will be emphasizing the importance of using design of experiments as a springboard into lean activities including 5S and Kaizen. The culture and quality elements that Six Sigma can provide to a manufacturing operation integrate well with lean methodology, particularly when it comes to reducing defects.

Lean Methods Used for Optimizing EMS Manufacturing — Cedro Toro is a lean sigma champion at Plexus. Plexus has integrated lean sigma into all that they do. Cedro will provide composite case studies that illustrate how lean design of experiment fuels other lean activities, including Kaizen and 5S. Case studies will illustrate how integration of lean methods results in better overall efficiencies in manufacturing operations.

Kaizen Event to Achieve Low-Volume Single-Piece Flow — This case study represents a Kaizen event having the objective to yield a value stream for a single-piece flow in a high-mix, low-volume, rapid turn environment.  Steven Myers, David Fissell and Stanley Bentley, of Diversified Systems, Inc., will focus on the importance of getting the right assumptions in place so that sustainable solutions are achieved.

Lean DOE for Thermal Coating Applications — Drawing upon his aerospace background, Aaron Spearin outlines how coating applications can be optimized. In this case study, thermal coatings are applied in critical high-reliability applications.

Registration Information

Early-Bird Discount: Register by November 3, 2009 and save 10% off prices shown below.
Group Discount: Register three individuals from your company at your location at the same time and receive the fourth registration FREE. Note: The discount will apply to the lowest cost registration.

Hotel Information

This event will take place at the Fiesta Inn, Tempe, Arizona.  The Fiesta Inn is located at 2100 South Priest Drive, Tempe, Arizona.  They may be reached at +1 480-967-1441 or toll-free at 800-528-6481.

The IPC room rate is $99.00/night for event participants.  To confirm your room at the discounted rate, please state that you are with IPC.  Please make your reservation by November 2, 2009, in order to take advantage of the special rate. After that date, rooms and rates are subject to availability. Make your reservation now!

Media Sponsors