Delphi Saginaw Plant 1 Case Study: Build Your House of Production on a Stable Foundation

A Lean Enterprise Institute case study of Delphi Steering’s Plant 1 in Saginaw, Michigan, which used basic stability work to cure chronic machine downtime after opening in 2004. It describes Pareto analysis of andon data, tool crib reorganization, week-long machine kaizen workshops initially led by retired Toyota veteran Tom Harada, TPM basics, and twice-daily performance board walks, with on-time shipping rising from 35 percent to 100 percent in a year.