IMPLEMENTING LEAN PRINCIPLES IN SHEET METAL PRODUCTION AREAS 17 MAR 04 Dean Haley MANBP I n t e g r i t y - S e r v i c e - E x c e l l e n c e MAN

Problem/Opportunity Air Force needs increase in B-52 engine cowl supply Bomber Production Section (MANPB) needs to increase productivity and capacity Top management desire for depots to incorporate Lean

MAN Objectives Decrease outsourcing requirement for B-52 cowls by increasing organic production Increase effectiveness and profitability in the Sheet Metal Production Section Provide a method for implementing Lean Production in Building 2101 Prove method in the Engine Cowl Shop Provide a plan for implementation in the remainder of the building

MAN Approach 1.Redesign the Process –Value Stream Upstream – Supply Downstream - Customer –Eliminate Waste Non-value-added asset transport Unnecessary labor –Standardize the Process Production Status Boards Two-shift operation

MAN Approach 2.Redesign the Work Area –Remove Unnecessary Equipment Co-utilize tools and workspace Design better furniture –Improve Product Flow –Maximize capacity for future workloads 3.Improve Ergonomics and Appearance –Implement employee suggestions –Improve safety

MAN Alternatives Considered Simultaneous Implementation –Implement in all shops concurrently Successive Implementation –Implement one or two shops at a time depending on size –Order from lowest to highest performing shops Contractor-managed Implementation –Assign team to expedite changes, facilitate contractor

MAN Analysis Provide the most effective implementation of Lean production in B2101 MUST –Not require hiring permanent employees –Not require line stoppage WANT (Objectives) –Lean (Waste, Value, Flow, Pull) –Performance (Effectiveness, Flow time, capacity) –Execution (Manageability, Affordability)

MAN Analysis

MAN Conclusions Simultaneous –Allows more radical layout changes –Faster implementation –Difficult to manage –More employees dedicated to effort Successive –Provided more uniform implementation –Better response to employees –Budget-friendly Contractor –Removes management problems –Less knowledge of operations –Expensive

MAN Recommendation Implement the process described successively in the remaining shops in B2101. –Begin 1 Apr 04 –Time to execute: 24 months

MAN Use of MSETM Materials Problem Solving/Decision Analysis –Kepner Tregoe Benchmarking Strategic Quality Leadership Enterprise Integration

MAN