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Factory Building Symposium on Lean Production

Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas . Empowering the Lean Team. Cavalier Homes, Inc. Addison, AL Michael Wade, Director of Manufacturing Operations. Cavalier Plant 2. Gaining Support for Lean. Inspire through example Build from small to large.

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Factory Building Symposium on Lean Production

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

  2. Empowering the Lean Team Cavalier Homes, Inc. Addison, AL Michael Wade, Director of Manufacturing Operations

  3. Cavalier Plant 2

  4. Gaining Support for Lean • Inspire through example • Build from small to large

  5. Form a lean team of volunteers Select highly visible electrical department for first success Push to get it done: complete overhaul applying the “Five Ss” Anthony Dickerson, water tester, committee chair Jerry Andrews, assistant production manager Dave Berry, QC inspector Mike Cornelius, exteriors Barry Doss, assistant supervisor - floor department Greg Gilliland, supervisor, partitions and electrical departments (rotating member) Roger Naylor, purchasing agent Buck Vickery, maintenance Greg Wiggins, production manager Johnny Wooten, QC manager Lean Committee Corporate Liaison Michael Wade, director of manufacturing operations Timothy Donaldson, value engineer Cavalier’s Strategy Improvements: • Combined electrical activities into one area • Streamlined material flow • Eliminated obsolete materials and equipment • Relocated closer to the point of use

  6. Leveraging the Initial Success • Celebrate success • Next, a major improvement

  7. Exteriors Department • Poorly organized work area resulting in multiple inefficiencies

  8. Exteriors Department • Equipment and materials • Conveyance • Loading • Storage Then Now Disposed of obsolete materials and fixtures Brought materials closer to point of use Material not close to point of use Arranged materials for ease of loading Designated storage locations and racks for all materials Excessive motion to supply materials into the area Obsolete materials and seldom used equipment clogging area Lack of storage system

  9. Highlights • Lean team mainly production employees • Team took initiative • Little upper management pushing • “Me too” factor • Workers own results • Strategy to sustain changes • Lean a framework for efficiency initiatives • Freedom to express constructive opinions

  10. Moving Forward • Expand “Five S” activity • Initiate more ambitious RPIs • Celebrate success • Form lean teams at all other facilities

  11. Lean Symposium

  12. Factory Building Symposium on Lean Production Manufactured Housing Research Alliance Jordan Dentz (212) 496-0900 x13 jdentz@research-alliance.org www.mhrahome.org

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