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VIDEO LIST
The Irwin/McGraw-Hill OM Video Series includes professionally developed videotapes showing students real applications of key manufacturing and service topics. Each tape contains plant tours to help students see how companies are using operations management concepts and techniques to be productive and competitive. Here is a brief summary of each segment:
Volume I - Tapes 1 & 2 (ISBN 0-256-12349-7)
Tape 1
Lean Production (13 minutes)
This segment shows and discusses how Lean Production is used at Caterpillar, Cummings Engine, and Navistar. Interviews with upper management at the three companies bring out the importance of customer-driven "pull" systems and how the companies employ KIT, Kanban, Jidoka, and MRP II to perform better.Quality (13 minutes)
George Bush at the Baldrige Award ceremony opens this segment, which goes on to list the seven basic tools. Then Zytec, Motorola, and Hewlett Packard are used as examples.The Manufacturing Process (10 minutes)
This segment presents the Hayes-Wheelright continuum, from customized, low-volume to mechanized, high-volume manufacturing. Most of the segment is on-site footage from a tool and die shop, Caterpillar, Ford, and Nucor Steel.Tape 2
Computer-Integrated Manufacturing (12 minutes)
This segment presents an on-site tour of the Nucor Steep mini-mill, focusing on the automation system. Included are interviews with the plant manager, controller, and caster foreman. It includes good illustrations of controls, process manufacturing, automation, and productivity.Manufacturing Inventory (11 minutes)
This segment contrasts Navistar’s high turnover-low inventory heavy truck manufacturing system with the high inventory-service parts business at Caterpillar. Interviews bring out Navistar’s reduction efforts as well as Caterpillar’s responsiveness and the corresponding effects on inventory and costs.Service (11 minutes)
This segment features First National Bank of Chicago and particularly the operations aspect of its check-clearing system. Interviews are included, which help reiterate the point that service businesses use "operations" principles to deliver quality "products."Volume II (ISBN 0-256-15967-X)
Service Systems and the Service-System Design Matrix (12 minutes)
First National Bank of Chicago is again highlighted with a survey of their customer services. This segment highlights the distinctions between automated low contact services and highly customized face-to-face encounters. It also relates these examples to other service companies and includes interview segments with managers.Improving Operations Methods (12 minutes)
This segment illustrates how Bernard Welding Equipment Company reduced set-up time and changed from a push to pull system to better serve their customers. The tape illustrates how a high variety of products (3,000 different configurations) can be custom assembled for quick response to customer orders. Topics touched on are Kanban, TQM, team approach, and JIT.Layout Improvements and Equipment Strategies (10 minutes)
This segment features Bernard Welding, this time illustrating a reconfigured layout based on process flow as opposed to process type. The segment also shows other improvements such as reducing the distance between related operations, renovating old equipment, upgrading to new technology, fail-safe measures, and use of Kanban.Supplier Development Outreach Program (16 minutes)
From Toyota, this tape describes changes and improvements made at Flex-n-Gate, a manufacturer in Danville, Illinois which supplies Toyota with pickup truck bumpers. Toyota Supplier Development Institute engineers consulted with Flex-n-Gate in the process. It includes factory footage and interviews with the purchasing manager, project manager, development engineer, and plant manager.Volume III ( ISBN 0-256-19528-5)
Reengineering at Caterpillar (11 minutes)
This segment describes a real program undertaken at Caterpillar’s Mossville Engine Center to reengineer the drawing process for engines. The five-step procedure this cross-functional group followed streamlined the process while improving customer satisfaction and quality. It also reduced time and costs. Interviews with team members are included.Washburn Guitars (12 minutes)
Washburn manufactures and sells over 150,000 guitars annually. This program provides an on-site overview of their job shop product system with special emphasis on production scheduling priorities and their use of a flexible n.c. machine.Shouldice Hospital (16 minutes)
This video, originally produced by Canadian National Broadcasting, describes the unique and specialized service product of Shouldice Hospital – hernia surgery. The entire process of delivery of the product is examined, along with the unique level of customer satisfaction.Volume IV – Tapes 1 & 2 (ISBN 0-256-21570-7)
Tape 1
Value-driven Production at Trek (9 minutes)
This segment describes the distinctive approach Trek uses to manufacture high quality, mass-customized bikes for their customers. The organizing framework is the Value Approach to designing and manufacturing products to match customer needs, as described by Melnyk and Denzler in Operations Management: A Value Driven Approach. On-site footage features interviews and examples of unique uses of material, testing and assembly.Scheduling Services – The United Solution (9 minutes)
This segment presents an overview of the scheduling system used by United Airlines in planning and delivering over 2,200 trips with 500 planes per day. Interviews with the developers of the PEGASYS computer system which starts the process, along with discussions with key flight scheduling, equipment scheduling, and maintenance scheduling personnel lay out the procedures and issues United must deal with to efficiently deliver service in the travel industry.Quality Product and Process Design at Detroit Diesel (11 minutes)
This segment describes the focus on quality, from design of products through the actual manufacturing of engines, including the highly successful Series 60 engine. Interviews with owner Roger Penske, the product manager and assembly workers are included. Also included are on-site examples of the use of technology and talent to increase quality through product and process design.Tape 2
Production Tour of the Vision Light System at Federal Signal (12 minutes)
This segment follows the production and assembly process for Vision Lights at Federal Signal Corporation. This begins with the original bill of materials schedule through incoming parts and kit inspections, and several assembly and sub-assembly processes. Interviews with the master scheduler, operations manager, and supervisors in purchasing are included and all footage is on-site.JIT at Federal Signal (12 minutes)
This segment presents the use of both "big" and "little" JIT concepts at Federal Signal to reduce waste, improve quality, and closely meet customer demand in manufacturing a variety of products. On-site examples of Kanban, work cells, and supplier relations are featured as well as short interviews with engineers and employees.Volume V (ISBN 007-366182-1)
TriState-Converting to JIT –Part 1- Assessment (10 minutes)
This video describes and shows the assessment and planning steps taken by Tristate Industries, a small midwestern supplier of metal products for the construction industry, as it ramps up to deliver a new product and double it’s output based on a new contract. Tristate president Don Keller and consultant Jim Therrien analyze the operation and plan the conversion to a just-in-time manufacturing system.TriState-Converting to JIT--Part 2- Implementation (9:50 minutes)
This segment shows how TriState implemented the new cells, eliminated a large percentage, of WIP and instituted a Kanban control system. An overview of the old and new systems are shown along with on-site interviews with employees and managers.International Logistics featuring American President Lines (11 minutes)
This segment tours the new Los Angeles harbor operated by American President Lines (APL) and describes the state of the art terminal operations. The use of GPS, and electronic tracking from point of origin to final destination through the harbor and electronic loading maps and schedules are illustrated. Capacity and speed issues are described along with the whole range of services provided by APL to global manufacturers and suppliers.Volume VI (ISBN 007-366193-7)
Product Design and Manufacturing at –TriState Industries (10 minutes)
This video provides an overview of several key design issues considered during the development and manufacturing process setup for new trailers made by TriState Industries in Indiana. Designer Don Keller discusses tools and methods he used as well as how customer preferences were taken into account. Illustrations of the manufacturing specifications in the plant are included.Project Management-Building the Alton ‘Super Bridge’ (10 minutes)
This segment follows the story of the building of the Alton, Illinois, super bridge across the Mississippi River and is based on a two-hour PBS documentary on the same subject. Highlights include descriptions of design, construction process, and even weather-related issues that project managers had to deal with in completing the project. Interviews with managers and contractors are included.Valuation of Operations at ABTco (11 minutes)
This video describes manufacturing product and process changes made at ABTco, a U.S. and Canadian building products producer which led to a 300 percent increase in overall corporate value in just one year. Besides ‘rightsizing,’ ABT reallocated and expanded capacity, invested in new and improved technology, reduced inventory, and developed and added 50 new products to their offerings. Interviews with key managers and footage from plants in North Carolina and Michigan are included.Volume VII (ISBN 0072437812) Coming: May 2000
Manufacturing Quality at Honda (12 minutes)
This segment takes viewers inside Honda American Manufacturing Inc. in Ohio where the company's very successful emphasis on quality through continuous improvement is showcased. The steps Honda takes to ensure quality in all stages of production and development of products is outlined and on site footage of team meetings, interviews, and examples are included.
A Day in the Life of Quality at Honda (9 minutes)
This segment highlights the proactive approach to quality Honda takes in their Ohio plant producing Civics and Accords. A behind the scenes look into a daily quality meeting is shown and several examples of proactive quality problem prevention are illustrated.
Statistical Process Control at Honda (6 minutes)
This segment illustrates Honda's use of statistical process control to monitor consistency and repeatability of processes. Control charts and reporting for a case study example are shown and described.
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