CAPT Red Hoover – Commanding Officer Mr. James D. Ward – Technical Director Lean Six Sigma Case Study: MRAP October 2008 Matt Shapiro, LSS Black Belt Krista.

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Presentation transcript:

CAPT Red Hoover – Commanding Officer Mr. James D. Ward – Technical Director Lean Six Sigma Case Study: MRAP October 2008 Matt Shapiro, LSS Black Belt Krista Walker, LSS Black Belt Speed to Capability Delivering Joint Interoperable Solutions to the Warfighter Through Engineering Excellence Rapid Prototyping Leveraging Technology

2 Why is Lean Six Sigma important? Federal government is pushing LSS Future contracts Just good business

3 Meeting Our Nation’s Demand Signal

4 Strategic to Tactical 4

5 Initial Surge Exceeded Existing Capacity Suboptimal Flow No Standard Work Areas Suboptimal Line Balance Excess Change over time Suboptimal Standard Work August 2007

6 Recipe for Success Lean Six Sigma + = 50+ MRAPS Per Day Process Improvement Team fully devoted to Lean Six Sigma activities: 1 Lead Program Black Belt 3 Execution Black Belts 6 Green Belts 1 MBB George Group Coach

7 Lean Six Sigma Line Design Station 1 Station 2 POU Storage POU Storage 5 Hours Final QA Inspection GFE Kits GFE Kits 1 Point-of-Use Hardware 2 GFE Carts 3 TAKT Boards Index Build Pace = 5 Hours Per Station 4 QA Line Checklist Visual Line Analysis

8 Lean Six Sigma Status Total Projects Identified 57 7 Projects in progress 44 Completed 6 future events Achieved 50 Integrated C4ISR Per day 5 Dec Completed 31 JAN ,000 Competed 21 AUG 2008 Capacity exceeds demand

9 Lessons Learned Senior Management Engagement is Key Inclusion of Subject Matter Expert (Worker) is critical Quick results – Challenge current conventions Standardized Work Flow is Critical

10 Transformation January 2008 (50 per day)August 2007 (5 per day) Questions?