1. 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. 2 Why is Lean Six Sigma important? Federal government is pushing LSS Future contracts Just good business

3. 3 Meeting Our Nation’s Demand Signal

4. 4 Strategic to Tactical 4

5. 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. 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. 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. 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 2008 3719 Completed 31 JAN 2008 10,000 Competed 21 AUG 2008 Capacity exceeds demand

9. 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. 10 Transformation January 2008 (50 per day)August 2007 (5 per day) Questions?