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  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 Workstations WIP Piles of WIP and excessive conveyance resulted in damaged doors One-third the WIP WIP over flowed into traffic aisles Clear traffic aisles Batch and queue Continuous flow work cell with no WIP between Then Now Workstations

Results IssueBeforeAfterChange Space 960 sq. ft.800 sq. ft. 16% less Raw doors in area 269 doors151 Doors 43% less WIP between processes 3 houses of doors0 100% less Completed door inventory 3 houses of doors2 houses of doors 33% less Flow time 40 hours20.4 hours 50% less Productivity with 2 team members 65 doors/day200+ doors/day 300% more

Final Finish  Productivity ThenNow Materials far from point of need, leading to excessive motion and conveyance Eliminated excess transport and removed unneeded items

Results Per houseBeforeAfterChange Walking 1.3 mi0.6 mi 54% less Trips % less Space n/a 615 sf less Time 40 min15 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 Alliance Jordan Dentz (212) x13 Factory Building Symposium on Lean Production