General Cable 
Intermediate level

Lean six sigma in a customer-driven pull system

Monday, Oct. 19 Location Code
7:15am-2:45pm Departure area 2, 2nd floor MT/02

Substantial improvements, engaged employees and customer focus

Encounter successful implementation of lean six sigma and related human factors that continue to yield revolutionary improvements in quality, inventory reduction, productivity and profitability performance. Hear about effective practices in components fabrication, marketing promotion delivery, custom product engineering, product development, service development and service delivery. Benefit from General Cable’s experience in culture change, employee engagement and continuous improvement(CI). Gain practical insights about visual replenishment systems, visual job instructions and how to avoid/overcome obstacles to progress.


Learn how to net dramatic improvements in quality and productivity through lean six sigma/CI practices. Get specifics on progress in components fabrication, product assembly, testing, warehousing, distribution, order processing, proposal preparation, marketing promotion delivery, custom product engineering, product development, service development and service delivery. Hear about lean six sigma practices that boosted quality, decreased inventories and increased profitability by reducing costs and working capital. Learn how upstream process improvements yielded downstream performance improvements. Understand how human factors affect achievement and sustainable improvements. Hear how every employee understands the importance of the company’s 12 core principles. Check visual replenishment systems between each process that enable lower WIP and better responsiveness to internal and external customers. Look for various communication methods, ranging from visual job instructions to shop floor planning/scheduling rooms and departmental/plant performance updates available on monitors around the plant.


General Cable is a leader in the development, design, manufacture, marketing and distribution of copper, aluminum and fiber optic wire and cable products for the energy, industrial, specialty and communications markets. It began its lean journey nearly ten years ago. Its culture of continuous improvement is defined by its 12 operating principles. The company has competitive strength in the breadth of its product line, sales and service, brand recognition, distribution and logistics as well as operating efficiency. The Lawrenceburg, KY plant is a 24/7 facility covering 364,000 sq. ft. It was a 2011 IndustryWeek Best Plant finalist.

Tour Host

Brett Ostrowski is the plant manager for General Cable in Lawrenceburg, KY. He strives to engage associates in all aspects of the business, with safety as a core value.

Restrictions / Requirements

To participate in a tour, all attendees must adhere to and respect the tour hosts' restrictions and requirements.
Non-adherence may exclude you from a tour.

  • No cell phones
  • No competitors
  • No recording devices
  • Hearing protection
  • Leather like closed-toe shoes (No high heels)
  • Long or short-sleeved shirt/blouse
  • Long pants (no shorts, skirts, dresses)
  • Safety glasses
  • Signed non-disclosure agreement
  • Steel-toed shoes