TBM's 2009 Perfect Engine Award


2009 Perfect Engine Site Award Winner - Mattel PTMI Jakarta

TBM Consulting Group, presented Mattel, Inc., the world’s largest toy maker, with the sixth annual “Perfect Engine Site” award, recognizing Mattel PTMI Jakarta for its commitment to “lean” excellence in manufacturing.

Award Criteria

  • Current engagement in a LeanSigma transformation with TBM
  • Completion of two years of LeanSigma transformation as of January 1, 2009
  • Commitment to the philosophy of investing in people, because people are the only appreciable assets in the business

Qualified applicants will be judged upon the following criteria:

  • Teamwork. The site must have trained at least 50 percent of its workforce in LeanSigma techniques – usually through Kaizen Breakthrough Events – and be committed to including a growing percentage of the workforce on kaizen teams.
  • Innovation. Managers of the transformation process will have a proven track record of innovation with LeanSigma principles, from creation of machine-build departments to new product teams or unique cross-training methods.
  • Breadth of Involvement. Besides including a percentage of the workforce on kaizen teams, this site will also include a large number of functional areas in LeanSigma work, from order taking to manufacturing, customer service, shipping, accounting and human resources.
  • Visual Management. The winning site will be an obviously visual workplace, with updated SQDC boards, hour-by-hour charts and other posted indications of area performance.
  • Flow and Takt Time.One-piece flow and the principles of rhythm based on takt time will be in place through at least 75 percent of the entire site, from order-taking to manufacturing and delivery of products or services.

Past Winners

Past winners of the award have included such lean leaders as:

  • ConMed, Utica, NY
  • WIKA Instrument Corporation, Lawrenceville, GA
  • Hayward Pool Products, Pomona, CA
  • Sealy Mattress Company, Batavia, IL
  • Vitromex, SA de C.V., Saltillo, Mexico
  • Kaiser Aluminum, Chandler, AZ
  • Invacare, Sanford, FL
  • Castech, SA de C.V., Ramos Aripe, Mexico
  • Gai-Tronics Ltd., Staffordshire, UK
  • Pella Storm Doors, Clear Lake, IA
  • Hubbell Power Systems, Inc., Aiken, SC