factory building symposium on lean production
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Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas. Finding the Right Fit. Clayton Homes Andersonville, TN. Brent Crabtree, Lean Advocate. Clayton Appalachia. Approach. Choose small scale initial events to ensure success and refine the process and team - PowerPoint PPT PresentationTRANSCRIPT
Factory Building Symposium on Lean
Production
January 29, 2007Austin, Texas
Finding the Right Fit
Clayton HomesAndersonville, TN
Brent Crabtree, Lean Advocate
Clayton Appalachia
Started: 1994 Location: Andersonville,
TN Home types: HUD Code Price point : Moderate Design: No
customization Production: 10 to18
floors/day Market area: Mid-eastern
states
Approach
Choose small scale initial events to ensure success and refine the process and team
Thorough and comprehensive execution
Door Build: Problems
Damage Congestion Productivity
WorkstationsWIP
Piles of WIP and excessive conveyance resulted in Piles of WIP and excessive conveyance resulted in damaged doorsdamaged doors
One-third the WIPOne-third the WIPWIP over flowed into traffic aislesWIP over flowed into traffic aislesClear traffic aislesClear traffic aislesBatch and queueBatch and queueContinuous flow work cell with no WIP betweenContinuous flow work cell with no WIP between
Then Now
Workstations
Results
Issue Before After Change
Space 960 sq. ft. 800 sq. ft. 16% less
Raw doors in area
269 doors 151 Doors 43% less
WIP between processes
3 houses of doors 0 100% less
Completed door inventory
3 houses of doors2 houses of
doors33% less
Flow time 40 hours 20.4 hours 50% less
Productivity with 2 team members
65 doors/day 200+ doors/day 300% more
Final Finish
ProductivityThen Now
Materials far from point of need, leading to excessive motion Materials far from point of need, leading to excessive motion and conveyanceand conveyance
Eliminated excess transport and removed unneeded itemsEliminated excess transport and removed unneeded items
Results
Per house Before
After Change
Walking 1.3 mi
0.6 mi
54% less
Trips 22 13 41% less
Space n/a n/a 615 sf less
Time 40 min
15 min
63% less
Highlights Always room to
improve Can make the
workplace better Team members
enthusiasm Management
commitment Data gathering and
analysis
Going forward
Incorporate lessons learned
Broadcast successes Tackle bigger projects Developing lean
training program Rolling out lean to
additional plants Change of mindset
Lean Symposium
Manufactured Housing Research AllianceJordan Dentz
(212) 496-0900 [email protected]
www.mhrahome.org
Factory Building Symposium on Lean
Production