The host for the October 5-9 event is Carlisle Tire and Wheel in Aiken, SC The host for the March 1-5, 2010 event is Hayward Pool Products in Pomona, CA. Hayward Pool Products, Inc. – Pomona CA Plant
The Pomona facility is located about 40 miles southeast of Los Angeles. The building is 300,000 square feet with about 1/3 of the building used for manufacturing, 1/3 for raw material storage and the reminder is used for distribution. Manufacturing consists of injection molding and assembly. The Pomona plant employs about 250 full-time employees utilizing temporary workers if needed to accommodate demand spikes. The products produced in Pomona are primarily designed for the in-ground swimming pool market. These products include four distinct pump families, two families of pool cleaners, two families of filters, skimmers and a wide variety of valves and spare parts. Raw materials are sourced throughout the world while the vast majority of plastic components are made in-house. The Pomona plant began its lean journey in 1999. On-time delivery was a constant source of customer complaints, yet inventory was at an all-time high. In fact, there was so much inventory, it impeded the company’s ability to grow the business. The set up of a molding machine could take six hours. Units were assembled in batches, placed into storage and then used at a later date. The plant’s first kaizen events emphasized quick mold changes and creating flow within the assembly cells. Workplace organization and safety improvements were a priority as well. Within a few years, kanban was implemented to schedule all WIP production and the entire assembly area was converted to “U”-shaped cells. More recently, Design for LeanSigma techniques were used to create a new pump that has been very well received. Five injection-molding machines were linked with the assembly cells they supply, creating true one-piece flow. All the while, the plant continues to address the fundamental aspects of its continuous improvement program. After ten years of implementing lean manufacturing, sales volume and profits have grown dramatically and customer satisfaction has never been better. Yet, we realize that the journey has just begun. We cordially invite you join us in this very special kaizen event and anticipate remarkable results. |
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Hayward Pool Products is the larger of two divisions of Hayward Industries, Inc. Company headquarters are located in Elizabeth, NJ with five domestic manufacturing sites; Clemmons, NC, Nashville, TN, North Kingstown, RI and Pomona, CA. Distribution for the Eastern US is handled by the Clemmons facility. Western distribution flows through the Pomona plant. International operations include manufacturing plants in China, Canada and France and sales offices throughout Europe.
