Video List
The Irwin 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.
 
Volume 01 - Tapes 1 & 2 (ISBN 0256123497)
Name Running Length in Minutes Description
Lean Production
(Tape 1)		 13 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
(Tape 1)		 13 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
(Tape 1)		 10 Also available on the TopTen DVD

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.
Computer-Integrated Manufacturing
(Tape 2)		 12 Also available on the TopTen DVD

This segment presents an on-site tour of the Nucor Steep minimill, focusing on the automation system. Included are interviews with the plant manager, controller, and caster foreman.
Manufacturing Inventory
(Tape 2)		 11 Also available on the TopTen DVD

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
(Tape 2)		 11 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 02 (ISBN 025615967x)
Name Running Length in Minutes Description
Service Systems and the Service-System Design Matrix 12 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.
Layout Improvements and Equipment Strategies 10 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, failsafing, and use of Kanban.
Supplier Development Outreach Program 16 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.
Volume 03 (ISBN 0256195285)
Name Running Length in Minutes Description
Reengineering at Caterpillar 11 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 Also available on the TopTen DVD

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 flexibile n.c. machine.
Shouldice Hospital 16 This video, orginally 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 04 (ISBN 0256215707)
Name Running Length in Minutes Description
Value-driven Production at Trek
(Tape 1)		 9 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
Scheduling Services
(Tape 1)		 9 Also available on the TopTen DVD

This segment presents an overiew 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
(Tape 1)		 11 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.
Production Tour of the Vision Light System at Federal Signal
(Tape 2)		 12 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.
JIT at Federal Signal
(Tape 2)		 12 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 o Kanban, work cells, and supplier relation
Volume 05 (ISBN 0073661821)
Name Running Length in Minutes Description
TriState-converting to JIT - Part 1- Assessment 10 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 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 system are shown along with on site interviews with employees and managers.
International Logistics featuring American President Lines 11 Also available on the TopTen DVD

This segment tours the new LA harbor operated by American President lines and describes the state of the art terminal operations of APL. The use of GPS, and electronic tracking from point of origin to final destination through the harbor, electronic loading maps and schedules are illustrated. Capacity and speed issues are described along with the whole range of services provided to global manufacturers and suppliers by APL.
Volume 06 (ISBN 0073661937)
Name Running Length in Minutes Description
Product Design and Manufacturing at Tri-State Industries 8:40 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 they took customer preference into account.Illustrations of the manufacturing specifications in the plant are included.
Project Management-Building the Alton 'Super Bridge' 12:52 Also available on the TopTen DVD and the Stevenson 8/e DVD

This segment follows the story of building of the Alton, Illinois super bridge across the Mississippi River and is based on a two-hour PBS documentary on the subject. Highlights include descriptions of design, the construction process, and even weather issues that project managers had to deal with in completing the project. Interviews with managers and contractors are included.
Valuation of Operations at ABTco 11:47 This video describes manufacturing product and process changes made at ABTco, a US and Canadian building products producer that 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 thier offerings. Interviews with key managers and footage from plants in North Carolina and Michigan are included.
Volume 07 (ISBN 0072437812)
Name Running Length in Minutes Description
Segment One- Manufacturing Quality featuring Honda 12 Also available on the Stevenson 8/e DVD

This segment introduces the general approach Honda Motor company has taken to ensuring top quality in its Marysville and East Liberty plants. Issues Honda dealt with are described as well as solutions such as rotating assignments for employees, teamwork in pursuit and elimination of problems, careful tracking and communication of causes of defects, and close communications with suppliers. Interviews with team leaders and plant managers are included.
Segment Two- A Day in the Life of Quality at Honda 9 Also available on the TopTen DVD

This segment shows specific quality oriented workings at the East Liberty Ohio plant. The day begins with a managers meeting outlining manufacturing results and variations that might lead to defects, and then follows as they are tracked down and examined in closer detail. Several examples of operations methods used to improve quality are shown along with some discussion of different control methods for specific types of operations at Honda.
Segment Two- Statistical Process Control Featuring Honda 7 This segment describes Honda's SPC efforts in several areas, and then focusses on one process test for door closing speeds. In the case study portion of the segment, an out of control situation is discovered and remedied.
Volume 08 (ISBN 0072504722)
Name Running Length in Minutes Description
JIT at McDonald's 12:03 Also available on the TopTen DVD

This video describes market, production, and service issues that McDonald's evaluated and considered in designing its new "Made For You" production system. Interviews with Claire Babrowski, Executive Vice President of World-Wide Restaurant Systems and Bob Marshall, Assistant Vice President of US Operations, as well as illustrations and demonstrations of the processes in the new JIT kitchen system are included.
'Made for You' Process Implementation featuring McDonald's 12:21 This program describes the implementation and change over to the new McDonald's "Made for You" system, a massive project completed in only 18 months. Claire Babrowski, Executive Vice President of World-Wide Restaurant Systems and Bob Marshall, Assistant Vice President of US Operations discuss local store and organizational issues they faced during the implementation process and how they dealt with them.
Robotics and Technology featuring Genesis Systems Group 11:52 Also available on the Stevenson 8/e DVD

This segment features the manufacturing process design done by Genesis Systems Group, a maker of robotic manufacturing equipment. System criteria, customer demands, analysis, design specifications and simulations are used in developing a new automated robotic welding system for an auto industry supplier, American Axle and Manufacturing (AAM), a Genesis client.
Volume 09 (VHS ISBN 0072870885 or DVD ISBN 0072870893)
Name Running Length in Minutes Description
Segment 1- Enterprise Resource Planning at Hillerich & Bradsby 16:15 Hillerich and Bradsby -maker of Louisville Slugger baseball equipment, Powerbilt golf, Louisville hockey equipment, over 300 different products in one manufacturing plant alone, had outgrown legacy operations management systems and so adopted an ERP system from SAP to integrate, centralize, streamline and better support their supply chain and customer service. This video features frank comments from owners Tom and John Hillerich along with interviews with plant managers and supervisors describing the implementation challenges, along with examples of their production processes.
Segment 2- Queueing-featuring the National Association of Realtors and Apropos Technology 12:54 Also available on the Stevenson 8/e DVD

The National Association of Realtors manages a Call Center named 'Information Central' for members which provides a high variety of research and information services via 7500 calls and 2000 web inquiries per month. This video describes how the NAR staffs, manages, and delivers these services and how it handles queueing issues. Apropos Technology designs and sells call center management software which Info Central uses to prioritize and handle queueing and delivery of customized service-both 'e-service' and normal call queries.
Segment 3- Service Design at Hotel Monaco Chicago 12:38 Also available on the Stevenson 8/e DVD

Hotel Monaco in Chicago, a Kimpton Group property, is a boutique class Loop property which competes for both business and leisure travel business by way of careful service design innovations matched to it's market niche. This video provides an overview of all of Monaco's services and examples of how it distinguishes it's "3 T's" of service from competitors. Staffing, 'experience' services, training, and the use of 'guestware' software are all illustrated along with interviews with managers.
Segment 4- Louisville Slugger Aluminum Bats: Plant Tour 8:35 Also available on the Stevenson 8/e DVD

This video takes a tour of the high tech aluminum bat manufacturing plant of Hillerich and Bradsby in Ontario California. H & B now make over 5000 bats a day and over 300 different models in this plant. This video walks through the manufacturing process from start to finish showing each step and treatment.
Volume 10 (ISBN 0072966319)-or DVD ?0072970634
Name Running Length in Minutes Description
Segment 1 - Queueing: Featuring Disney World 9:45 This video provides an overview of a variety of methods of managing and improving customer satisfaction by reducing waiting time and perceived waiting time in Disney theme parks worldwide. The concept, testing, implementation, and results of one 'imagineering' initiative at Disney World--the innovative Fast Pass system are described and highlighted. Fast Pass reduced waiting time, increased 'rides per capita' a Disney management measure, and redistributed traffic flows, all leading to improved customer satisfaction at Disney World.
Segment 2 - Process System Improvement: Strategy and Planning featuring Gortrac 12:11 First of two parts, this segment describes Gortrac, a manufacturer of flexible tracks for housing cable and hoses in industrial applications, and the strategy it used to improve their process and system. Gortrac management identified 3 year goals and objectives involving inventory levels, quality, product diversification, and throughput. A key component of the strategy was employee and team participation.
Segment 3 - Process System Improvement: Implementation featuring Gortrac 10:17 Also available on the Stevenson 8/e DVD

This second of two segments describes and illustrates specific implementation accomplishments such as redesigned work cells, techniques used to reduce WIP and parts inventory, and several employee suggested kan-bans and card systems to reduce waste and rework and increase productivity. In addition, Gortrac added a new product successfully earlier than called for in the company strategic goals.
Segment 4 - Operations Management: featuring St Alexius Medical Center 17:07 This program presents an overview and interviews describing the service specialization of St. Alexius, a Chicago based hospital, particularly their pediatrics and pediatric emergency systems. The Hospital utilizes Operations concepts such as strategic planning, process analysis, layout design, quality and safety monitoring and tracking, capacity planning, work design, and customer satisfaction and staff training to provide specialty care and emergency treatment for acute child patients.
Volume 11 (ISBN 0073045152.) DVDRom ?Now featuring scene selection menus...
Name Running Length in Minutes Description
Segment 1 - What is Operations Management? 13.57 This video provides an introductory survey of the applications of Operations management concepts in a wide variety of service and manufacturing industries. Brief examples from companies such as McDonalds, Hillerich and Bradsby, Disney, Honda and others are used to introduce students to the field of OM and it?s importance in companies.
Segment 2 - The Product Process Matrix 14.10 This segment presents the classic Hayes Wheelwright product process matrix, illustrating the concept of matching products with processes in manufacturing. The high volume standardized continuous processes of British Petroleum are contrasted with mass production at Honda, batch processes at Caterpillar, and the job shop of AED vision. Onsite footage and descriptions of the system process and capacity is included for all f4 examples.
Segment 3 - The Service System Design Matrix 10:55 This video features Chase Bank to illustrate and provide the variety of customer contact systems used in service industries. Onsite examples and interviews are included describing the entire range of Chase Bank services, from the low contact methods such as mail, onsite technology and internet banking, all the way up to the highly customized and unique ?Private Client Services? which Chase delivers to top end investment clients.
Volume 12 (ISBN 007326881X) DVD with scene selection and special features
Name Running Length in Minutes Description
Segment 1 - Flexible Manufacturing: Featuring Ford ? Chicago Assembly Plant 14:40 This video describes and examines the new Ford Chicago Assembly plant which manufactures multiple models including the Ford 500. The CAP and the related Supplier Campus constitute the largest and newest facility in North America and flexibility has been built into the system which reduces model changeover times from 8 months to less than 1 month. Interviews and on site footage describe the planning and start up activities, the use of PLC robots and Geostations, common vehicle architecture and supplier coordination needed to achieve such flexibility.
Segment 2 - Ford - Supplier Relationships ? Fords CAP Supplier Campus featuring SY 10:30 In the Ford CAP Supplier campus the company partnered with Tier 1 suppliers to plan coordinated flows, reduce travel distance and time, and improve quality overall. SY is both a Tier 1 supplier of wiring systems for Ford but also a Tier 2 supplier to other Tier 1 suppliers in the CAP campus. The video features system overviews, on site footage and interviews with both SY and Ford managers describing how 77 items (versus 8 in other Ford plants) are sequenced into the Ford assembly system from suppliers.
Segment 3 - Ford ? Total Supply Chain Management 10:50 This video provides an overview of the Ford Supply chain as it has been improved at CAP, including interviews with Ford executives. In the CAP Ford used an 8 criteria ranking system to work with Suppliers and sub suppliers, and at the same time designated lead suppliers to coordinate and manage flow into the new plant. At the Chicago plant, inventory turns are double what they were at the previous Taurus plant, spare parts are only 3% of total campus inventory (versus 97% previously), and the ?in line vehicle sequencing? system keeps only 90 minutes of any supplier part within the plant.
Segment 4 - Service Management Featuring Levin BMW 11:30 Levin BMW sells and services BMW?s in Northwestern Indiana and this segment walks through their overall system. Topics discussed include their interaction with BMW, design and layout choices intended to delight customers, staffing and scheduling, and the Levin Dealership?s overall emphasis on customer satisfaction as a competitive strategy.
Segment 5 - DHL ? Global Delivery Service 12:45 DHL is the leading global delivery company servicing over 200 countries and generating over $50 billion in revenue annually. This video provides an overview and the metrics of their global network as well as on site interviews and illustrations from the Miami Gateway location. Their total system is illustrated step by step. DHL executives also describe strategic decisions such as the acquisition of Airborne, and service design innovations such as partnering with US and Canadian Customs.
Segment 6 - BP ? Greenhouse Gas Reduction Project 13:40 BP initiated a project to reduce greenhouse gas emissions in 1998 with a goal of completion by the year 2010. Their goal was to reduce total global emissions within the company to 10% below the levels of 1990. This video focuses on the process and approach of the western US operations and describes their prioritization, costs, and the results they achieved. BP achieved it?s corporate goal in 2001, 9 years ahead of schedule.
Volume 13 ISBN 987-0073278261
Name Running Length in Minutes Description
Project Management at Six Flags, New Jersey 11:23 This video highlights the key components of successful project management through a look at the construction of Kingda Ka, the world?s tallest and fastest roller coaster, at the Six Flags theme park in New Jersey. Larry Chickola, Chief Corporate Engineer on the project, discusses the planning, scheduling, and logistics that went into the roller coaster?s timely completion. He also touches on the constraints and challenges of the project, including delays caused by weather conditions and the vast number of workers at the site.
Service Processing at BuyCostumes.com 10:24 BuyCostumes.com, the fastest growing online apparel company, is featured in this video on service processing. Interviews with the company?s purchasing director, costumer service manager, warehouse manager, and logistics coordinator provide insight into the processes and procedures necessary for effective order fulfillment, such as stocking, sales and inventory projections, warehouse & customer service staffing, purchasing and forecasting. Since over 50% of the company?s sales occur 6 weeks before Halloween, the unique challenges of buying with a long lead time are illustrated in particular.
Six Sigma at Caterpillar 12:27 The quality improvement strategy of Six Sigma is explained through Peoria, Illinois-based company Caterpillar and its broad implementation of the process on over 40,000 projects since 2001. Focusing on the tools and benefits of Six Sigma in improving quality and performance by decreasing defects and costs, special note is given to the development of Caterpillar?s ACERT technology to reduce emissions in response to Clean Air Act regulations. Also featured is supplier Solar Turbines and their application of Six Sigma and value-stream mapping to reduce inventory and improve cycle time, capacity, and delivery performance (from 10-20 days to 4-5).
Volume 14 ISBN 978-0073278780
Name Running Length in Minutes Description
Service at Zappos.com 13:14 Zappos.com currently stocks more than 3 million shoes, handbags, clothing items and accessories from over 1,100 brands. Their slogan, ?Powered by Service? highlights their emphasis on a service culture. Featured in this video is the company?s employee training process as well as their random access inventory system and distinctive spider-merge conveyor system which speeds shipping time.
Green Manufacturing at Zerox 9:42 This video focuses on Xerox?s goal to use energy and raw materials as efficiently as possible while reducing the amount of waste through sustainable product design. Xerox?s Green Manufacturing takes back end-of-life equipment from its customers, and then either remanufactures the equipment or reuses and recycles the parts. Using a process called Signature Analysis, Xerox determines the useful life of parts and whether they can be reused or should be disassembled. Includes discussion of quality assurance and the company?s adherence to ISO standards.
Burton Snowboards-manufacturing Design 19:34 This segment takes the viewer on a comprehensive plant tour of the Burton Snowboards factory in Vermont, showcasing their unique manufacturing and design process. Focusing on their ?Just enough system? and built-to-order process, the step-by-step, hand-customized board build process is presented in depth.


 
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