by Dave Rizzardo, Associate Director

Our April 2026 MWCC Lean Facility tour took place at the Flowserve facility in Taneytown, Maryland. They are a global leader in manufacturing and aftermarket services for comprehensive flow control systems, including pumps, valves, and seals. The processing in Taneytown includes machining, assembly, repair, and testing. Following is an overview of the morning which included hearing about and seeing a number of impressive Lean practices.

We started the morning learning about Flowserve and the corporation’s overall focus on Lean/Continuous Improvement which includes a world-class commitment to safety. They don’t just talk and train about safety and incorporate the typical safety practices, but they do much more. Support systems such as their “safety-observation” process and recognition practices shine a continuous light on safety, but even more importantly, these practices influence and change workforce behaviors. That is how you create a true safety culture and align with the “Respect for People” principle of Lean. (What could be more disrespectful than not providing a safe workplace?)

During the tour we saw various Lean practices in action. Their 5S/Workplace Organization practices were impressive for any type of processing environment, however, considering Flowserve’s processing environment which includes machining and fluid testing, it was nothing short of amazing. One of the other practices which really stood out to me and provides a great indication of their commitment to Lean and continuous improvement culture, was their daily management system. This included KPI/Communication Boards in each area which shouted out the current status, issues, action, and status. This was supported by a tiered huddle system which escalated issues when necessary. The simple, yet extremely effective, daily management system is one which should be emulated by all companies.

We heard and witnessed numerous other Lean practices, but probably the most obvious indication of their commitment to Lean is their targeted improvement efforts. Specifically, their ongoing focus of developing standard work within a high variety processing environment, an enhanced andon system, and their Lean maturity assessment system were highlighted. In summary, it was a great Lean learning morning provided by the Flowserve team! Thanks for sharing your impressive Lean journey and making us all smarter!