Leading the Way to Competitive Excellence: The Harris Mountaintop Case Study

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Contents
Includes links to sample excerpts from the book

Endorsements

A. Blanton Godfrey, Juran Institute, Inc.

Eliyahu Goldratt, Avraham Y. Goldratt Institute

John Hradesky, P.E., The National Summit Group, Inc.

Dr. Michael Cowpland, Corel Corporation

Author information

Leading the Way to Competitive Excellence
The Harris Mountaintop Case Study


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Order from ASQC Quality Press

Experience the real story of Harris Semiconductor's Mountaintop plant as it went through a radical turnaround by adopting state-of-the-art quality management techniques.
Understand the active role of management needed during reorganization, and learn the tactics that can eliminate tired paradigms.This book teaches principles, not recipes, and chapters focus on the programs and activities that, when used together, create the synergy needed to successfully transform an organization.

What does the mythical hero Hercules have to do with a modern book on competitive leadership? Alexander the Great chose Hercules as a role model, and Alexander was history's first paradigm buster. He succeeded by doing what everybody "knew" was impossible, and by finding innovative solutions to complex problems. We therefore choose Alexander, and his role model Hercules, as symbols of innovative, breakthrough thinking.

CONTENTS: (per original manuscript)

Editor's Introduction
Introduction
Paradigm Busters
Culture as Foundation
Teaming to Win
Customer Contact Teams: Improving Communications And Quality
Zero Scrap Actions
Total Productive Maintenance
Synchronous Flow Manufacturing
ISO 9000 and QS-9000
Integrated Yield Management
Statistical Methods
The Internet
Bibliography

Editor's Introduction

Introduction

Return to contents

Paradigm Busters

Alexander and the Gordian Knot: artwork by Beth Hollock

His Role Model

Return to contents

Culture as Foundation

Introduction

Adaptability and Organizational Survival

Proactive Union Leadership

Culture's Effect on the Change Process

The Human Resource's Department's New Role

Return to contents

Teaming to Win

Open, Flexible Culture

Shared Responsibility: The Star Concept

Variable Pay

Improving Communication

Management Commitment: The Vital Ingredient

Return to contents

Customer Contact Teams: Improving Communications And Quality

Introduction

Getting Ideas from Customers

Team Preparation

Customized Product Improvement

Experience to Date

Taylorism: Brains at the factory gate

Return to contents

Zero Scrap Actions

Return to contents

Total Productive Maintenance

Application of Cross-Functional Work Teams

OEE and Cost Accounting

Return to contents

Synchronous Flow Manufacturing

Introduction

The Cost Model's Dangerous Deficiencies

Be Careful What You Wish, You Might Get It.

(Pig-swallowing by pythons and boa constrictors is an example of the "push material into the production line" approach. Note the inventory bulge, or bubble. "Mama": photo courtesy of the Serpent's Den, Route 209, Milford, PA 18337, 717-296-5877)

Small Batches and Customers

Balanced Capacities and Other Mythical Entities

TPM: Focus Organizational Resources on the Decisive Operation

Return to contents

Java Script simulation of the matchstick-and-dice experiment in Goldratt and Cox, The Goal.

ISO 9000 and QS-9000 also see our new book (May 2000):

Roadmap to ISO 9000 Certification

QS-9000's Influence on Registrar Selection

Calibration and Capability

National Institute of Standards and Technology (NIST)

Evolution of Standards

Return to contents

Integrated Yield Management

Return to contents

Statistical Methods

Key Issues

Pictures and Diagrams for Statistical Training

Interactions

Multiple Trials versus Single Trials

Return to contents

The Internet

Rapid Technological Change: A Perspective

Organizations Must Anticipate Change and Adapt to it

The Intranet at Harris

"Mene, mene, tekel, upharsin." The handwriting is on the wall. Your market share may indeed be divided, and given unto the Medes, Persians, and anyone else with an Internet presence. Data are from Jared Sandberg, "Making the Sale," The Wall Street Journal, 6/17/96, page R6. In 1995, retail sales via the Internet were $350 million, or 0.021% of the total ($1.7 trillion) in the U.S. retail industry. The solid points in the figure are the article's projections for on-line shopping revenue through 2000. While extrapolation is always dangerous, the Net will play a decisive marketing and sales role in the next century.

Advertising Effectiveness

Adding a Web Site to Search Engines

Return to contents

Bibliography

Return to top
Endorsements

Juran Institute

"For the last thirty years industry has been bombarded with new management theories. Each was quite revolutionary, each attracted followers, but in total they created the confusion that led to the phrase 'the program of the year.'"
"While the inventors and their zealous disciples were forcefully arguing which theory was correct (or at least more powerful) some of them started to notice that these theories are not in conflict. Actually they are parts of the same puzzle."
"This book is the first that shows how to put them all together - in reality. Moreover, through the description of how it was done a new and very encouraging message emerges: implementing all facets of the new way to manage a plant is easier then implementing just one of them. It is written by people who have implemented and enjoy the results and it clearly shows; in the depth of understanding, in the practical advice and in the resulting enthusiasm. A great contribution to the know-how."

Avraham Y. Goldratt Institute

ASQC Quality Press

Critical Chain

The Goal

It's Not Luck

"The breadth of the contents and examples provide the 'what' and 'how to's' which can be applied to any company to take it to the next level."

National Summit Group

Total Quality Management Handbook

ASQC Quality Press

, Productivity and Quality Improvement

McGraw-Hill

"Marshall McLuhan once said, 'the media is the message.' The Internet chapter in Leading the Way to Competitive Excellence celebrates the free-flowing, global, and instantaneous nature of the Internet and its revolutionary effect on the delivery of news and business communications. Levinson has certainly expressed the emerging trends of corporate Internet use. It's as though he has put his finger on the pulse of an innovative company like Corel and penned what we perform on a daily basis."

Corel Corporation

Return to top Authors

John L. Benjamin ISO 9000 and QS-9000	John L. Benjamin is an Engineering Leader for the Process Development and Photo and Etch groups at the Harris Semiconductor facility in Mountaintop, Pennsylvania. He has been at this facility for eight years. Prior to this assignment, John was with the Semiconductor Division of the General Electric Company in various individual contributor and leadership roles. John holds a Masters degree in Business Administration with a concentration in Operations Management from the University of Scranton and a Bachelors degree in Materials Engineering from Rensselaer Polytechnic Institute. John holds one patent and has co-authored six papers. John is the Management Representative ISO 9002 at Mountaintop, and served in this position during the successful certification of the Mountaintop facility in 1994.
Roger A. Bishop Culture as Foundation	Roger A. Bishop has been Manager of Human Resource Operations at the Harris Semiconductor facility in Mountaintop, Pennsylvania for the past ten years. Prior to this assignment, Roger held various Human Resource positions in General Electric and RCA facilities in New York, NY, Princeton, NJ, Boston, MA, Lancaster, PA and Vancouver, Washington. Roger holds a masters degree in Human Resource Administration from the University of Scranton, Scranton, Pennsylvania and a Bachelors degree in Advertising from Ferris State University. Roger is an adjunct faculty member of the University of Scranton Graduate School of Human Resource Administration. He is also a member of the board of directors of the Greater Wilkes-Barre Area Labor Management Council and the Tri-County Personnel Association.
Michael A. Caravaggio Total Productive Maintenance	Michael A. Caravaggio, Engineering Leader , wafer probe, Calibration and Special Projects. He has a degree in Electrical Engineering Technology from Pennsylvania State University and has been involved with power discrete devices at the Mountaintop location since May 1961. He has held engineering and management assignments ,in equipment maintenance ,calibration ,equipment and process engineering ,and manufacturing with RCA, GE, and Harris Semiconductor at the Mountaintop location. He provides the leadership for several diverse engineering project teams and is Mtop's TPM Champion, providing the TPM emphasis for the plant.
Clinton A. Chamberlin ISO 9000 and QS-9000	Clinton A. Chamberlin is the Manager of Quality and Reliability at the Mountaintop Facility, and has held various positions in the field of Quality and Reliability since joining the RCA in 1973. He pioneered the use of Statistical Process Control and real-time Product Reliability Monitoring at the Mountaintop plant. Clint holds a Masters degree in Engineering Management from Syracuse University, and a Bachelors degree in Electrical Engineering from Bucknell University in Pennsylvania.
Robert C. Fitch, Jr Integrated Yield Management	Robert C. Fitch, Jr. (Master of Science, Electrical Engineering, Air Force Institute of Technology) has been the Integrated Yield Management project leader at Harris Mountaintop since November, 1995. Prior to employment with Harris, Bob was a reliability and quality assurance engineer with Motorola's Logic Division, Reliability and Quality Assurance Group, where his focus was on failure analysis of logic integrated circuits and developing advanced FA techniques such as emission microscopy and voltage contrast. Before Motorola, Bob was an Air Force Officer for 11 years. He spent three years on high power, microwave, gallium arsenide transistor development and technology transfer to industry. He earned his Bachelor of Science degree in mechanical engineering from the Pennsylvania State University, and his Bachelor of Science in electrical engineering from Louisiana Tech University.
Raymond T. Ford Introduction	Raymond T. Ford has been Director of Plant Operations at the Harris Semiconductor facility in Mountaintop, Pennsylvania for the past four years. Prior to this assignment Ray held various manufacturing positions for RCA, GE, and Harris at Palm Beach, Florida, Syracuse, New York, and Research Triangle Park, North Carolina. Ray holds a Bachelor of Science Degree in Electrical Engineering from Wilkes University, Pennsylvania.
Jeffrey E. Lauffer Paradigm Busters	Jeffrey E. Lauffer, (BS Physics, Indiana University of Pennsylvania), has been involved with power discrete MOSFETs at the Mountaintop location since their inception during the late 70's. He has held increasing responsibility assignments in process engineering and management with RCA, GE, and Harris Semiconductor at this location. He was the wafer fab manager responsible for designing, building, ramping, and running the current 6" Power MOS fab from 1987 to 1991. Jeff is presently the engineering manager for the 4 manufacturing wafer fabs (4", 5", 6" and 8") and epi area at the Harris Mountaintop plant.
William A. Levinson Paradigm Busters, Statistical Methods, The Internet	William A. Levinson is a staff engineer and industrial statistician at Harris Semiconductor's plant in Mountaintop, PA. He is author of The Way of Strategy (1994, ASQC Quality Press) and of Levinson and Tumbelty, SPC Essentials and Productivity Improvement: A Manufacturing Approach (1997, ASQC Quality Press). A graduate of the Pennsylvania State University, he holds master's degrees in engineering, business administration, and applied statistics from Cornell University and Union College. He holds ASQC certifications in quality engineering, reliability engineering, quality management, and quality auditing. He is a registered Professional Engineer in Pennsylvania.
Robert F. Longenberger ISO 9000 and QS-9000	Robert Longenberger has been involved in power semiconductor operations since the early 1970s with RCA Solid State Division, GE Solid State, and now Harris Semiconductor at the Mountaintop, Pennsylvania, facility. His current position entails the operational and engineering responsibility for the Calibration Laboratory in addition to manufacturing support for the 4, 5, 6, and 8 inch wafer fabrication areas. He is a Summa Cum Laude graduate of Luzerne County Community College (Pennsylvania) earning an Associate of Science degree in electronics.
Robert E. Murphy Synchronous Flow Manufacturing	Robert E. Murphy, Jr. has been Manager of Manufacturing at the Harris Semiconductor facility in Mountaintop, Pennsylvania for the past six years. Prior to this assignment, Bob has held various manufacturing positions in Harris facilities in Palm Bay, Florida and Poughkeepsie, New York. Bob holds a masters degree in organizational management from College Misericordia, Pennsylvania and a Bachelors degree in business administration from Florida Institute of Technology. Bob has attended the Avraham R. Goldratt Institute and has earned the title "Jonah". Bob is currently leading efforts within Harris Semiconductor in the use of "Theory of Constraints" and "Synchronous Flow Management" applications.
Allen L. Sands Customer Contact Teams: Improving Communications and Quality, and Zero Scrap Actions	Allen L. Sands (BS - Electrical Engineering, The Pennsylvania State University), has been manager of world-wide Power Product Engineering, Quality & Reliability, and HiRel Operations for the past 5 years. Prior to this assignment, Mr. Sands has held various engineering and management positions with RCA, GE, and Harris Semiconductors in design, quality/reliability, product engineering, process development, and wafer fab. Mr. Sands has been the recipient of various achievement awards and has is a holder of the 'Jonah' certification in TOC from the Avraham R. Goldratt Institute.
Puneet Saxena Synchronous Flow Manufacturing	Puneet Saxena has been a Manufacturing Analyst with Harris Semiconductor for the past four years. Currently, he is responsible for managing production in Mountaintop's 4-inch wafer fab and epitaxial growth areas and is actively involved with the training and implementation of Synchronous Flow Manufacturing and the Theory of Constraints. Puneet is a certified Jonah and a TOC Production Application Licensee from the Avraham Goldratt Institute in New Haven, Connecticut. He has been appointed as Harris Corporation's Best Practice Expert for capacity modeling in semiconductor fabrication and probe facilities. Puneet holds a BS degree in Mechanical Engineering from the Indian Institute of Technology in Kanpur, India. He also holds an MS degree in Mechanical Engineering and an MBA with a concentration in Operations & Logistics management from the Ohio State University in Columbus, Ohio.
Stephen E. Tetlak Integrated Yield Management	Stephen E. Tetlak ( Current enrolled M.S. Electrical Engineering, Wilkes University; B.S. Electrical Engineering Technology, Penn State University ) is a Yield enhancement Engineer in the Integrated Yield Management Group at Harris Semiconductor since Sept 1994. Current Position entails Systematic Failure Analysis, Yield Analysis, Yield partitioning, of both Short Loop and Long Loop Yield Detractors used to drive Defect Density Reduction of manufacturing facilities Fab 5, 6, and 8.
Martin L. Wentz Teaming to Win	Martin L. Wentz, (B.S. Business Administration, Wilkes University; A.A.S. Electrical Engineering Technology, Luzerne County Community College) has been with Harris since 1986. Starting as a senior production supervisor, he has held positions of increasing responsibility, including an assignment at SEMATECH (Austin, TX) as technology transfer manager. He is currently manager of training and organizational development for the Mountaintop plant. Martin has been actively involved in team development for most of his career and has published several technical articles on the subject.

Standing, left to right: Al Sands, Ray Ford, Stephen Tetlak, Jeff Lauffer, Marty Wentz, Bob Murphy, Bob Fitch, Puneet Saxena, Bill Levinson, Roger Bishop. Seated, left to right: Clint Chamberlin, Mike Caravaggio, Bob Longenberger, John Benjamin
On table (center): Velociraptor dinosaur, mascot for Mountaintop's 8-inch (200 mm) semiconductor plant

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CONTENTS: (per original manuscript)

John L. Benjamin

Roger A. Bishop

Michael A. Caravaggio

Clinton A. Chamberlin

Robert C. Fitch, Jr

Raymond T. Ford

Jeffrey E. Lauffer

William A. Levinson

Robert F. Longenberger

Robert E. Murphy

Allen L. Sands

Puneet Saxena

Stephen E. Tetlak

Martin L. Wentz