Packard honors perfect plants

Two Packard plants are honored for a zero-defect rate during a critical two-month period.
THE VINDICATOR, YOUNGSTOWN
By DON SHILLING
VINDICATOR BUSINESS EDITOR
WARREN -- While people may not be perfect, Delphi Packard Electric Systems has proved that industrial plants can be.
The maker of wiring harnesses and components honored two of its plants Wednesday for reaching perfect quality during July and August, the period when automakers launch new or updated models. One of them, Plant 48, has not shipped any defective parts this year.
Plant 15, also honored for perfect quality in the launch period, has had a defect rate of less than 0.25 parts per million this year.
Treated to lunch
Packard marked the occasion by providing lunch to the 620 workers at both plants, which are in its North River Road complex. It also awarded $5,000 to each of two charities selected by the workers -- Warren Family Mission and Hospice of the Valley.
Delphi Corp., the Michigan-based parent company of Packard, started the quality competition last year. Both plants 15 and 48 were honored then, along with Plant 8 on Dana Street.
Plant 15 makes battery cable; Plant 48 makes wiring components that are needed as repair parts.
Dan Lazor, manager of both plants, challenged the workers to continue to focus on quality so that they can have a "three-peat" next year.
Crucial months
Mark Heacox, director of manufacturing for Packard's Ohio operations, said July and August were selected because those are crucial months for automakers. New vehicles are being launched, and automakers are trying to change some people's perception that new models should be avoided because they are more likely to have quality problems.
The only plants that were eligible to be honored are those that ship directly to automakers instead of other Delphi plants or other suppliers.
Packard's Cortland plant hasn't shipped any defective parts since it was remodeled in 2000, but it doesn't send its plastic connectors directly to automakers. Seven of Packard's area plants qualified for the competition.
Worldwide, Packard had 41 plants eligible and 12 achieved perfection during the launch period.
Tom Sosnowchik, Packard's director of global customer satisfaction, said customers are increasingly demanding better quality.
John Sefcik, director of manufacturing for Packard United States operations, said this expectation makes it harder to achieve a zero-defect rate.
In the past, a single problem with a wire or connector might be handled by an engineering representative informing someone from Packard. That communication wasn't recorded as a defect in calculations.
Today, everything is written up as a customer complaint, which counts in the defect rate, Sefcik said. "Their expectation is perfection."
Packard's area plants have had a defect rate of eight parts per million through October of this year.
shilling@vindy.com