Factory Building Symposium on Lean Production January 29, 2007 Austin, Texas

Hi-Tech Housing, Inc., Bristol, IN Butch Berlin Assistant Production Manager Wall Production and Changeover Time

Hi-Tech Housing  Started:1991  Location:Bristol, IN  Home types:HUD Code and modular  Price point :Mid to high-end  Design:Substantial customization  Production:2 to 4 floors/day  Market area:Midwest

Partition Build  Wall build cycle time too long  Not keeping up with wall set  High visibility area

Partition Build  Replenishment  Equipment  Appearance No designated storage locations and consumed floor space A place for everything acts as a visual for material handlers Two wall tables, one rarely used Focus resources on one expanding jig Disorganized and dirty appearance Painted, resealed and cleared makes it obvious when something is out of order Then Now

Results  One-time cost of the RPI event: $8,000  Annual labor savings: $35,000  Reduced space requirements by 1,250 sf

Line Moves: Changeover Time  Plant floor procedures Waiting for lines to be moved and floor to be cleaned Sweeper preps before each module in sequence Then Now

Results  Reduced changeover delay by an average of 13 person-minutes per station  At 2 moves per day: labor savings of $13,400 per year  At 4 moves per day: labor savings of $26,800 per year  Less damage to air and electrical lines  Improved safety  Better morale

Highlights  RPIs scheduled to minimize disruption to production  Strong management support  RPIs focus on improving the area  Meetings spaced to give workers time to think  Strong enthusiasm

Going Forward  Comprehensive “Five S” program  Numerous other major RPIs  Working with suppliers to push lean upstream

Lean Symposium

Manufactured Housing Research Alliance Jordan Dentz (212) x13 Factory Building Symposium on Lean Production