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Factory Building Symposium on Lean Production

Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas . Four Seasons Housing, Inc. Middlebury, IN Austin Baidas, CEO and President. Level the Load. Four Seasons Housing. Objective: Balance the Line. Eliminate non-value added (NVA) activity

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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. Four Seasons Housing, Inc.Middlebury, INAustin Baidas, CEO and President Level the Load

  3. Four Seasons Housing

  4. Objective: Balance the Line • Eliminate non-value added (NVA) activity • Reduce cycle time variability • Station to station • Floor to floor

  5. Strategy • Map product flow • Analyze data to identify causes of cycle time variability • Implement solutions that reduce NVA and control cycle time variability

  6. Sources of Variation • Double vs. single floor stations • Variation in complexity from A to B half Tactic: Convert single floor stations to double floor stations

  7. Then Interior Walls Upper Cabinet HVAC Mezzanine Cabinet Tops CabinetShop Plumb & Tile Cabinet Shop Plumb& Tile 2A HVAC, H2O, DWV Raw Material End Wall 5 Interior Walls 4 Cabinet Set 3 Plumb, Util., Floor 2C Decking 6 End, Side, Drywall & Electrical Side Wall Jig Raw Material Side Wall Jig 7 Side, Drywall, Elec. Roof Ass’y 8 Marriage, Drywall & Electrical Raw Material 2B Pre-Floor Mud Pit Mud Pit Raw Material 9 Roof Set, Drywall & Electrical Heater Raw Material 1B Post-Frame 1A Frame Raw Material 10 Rough Roof, Exterior & Interior Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish 11 Shingle, Siding & Interior Paint, Dry, Finish Paint, Dry, Finish 13 Mud, Dry, Prep 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 12 Sofit & Fascia Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish

  8. Now HVAC Mezzanine Interior Walls Upper Cabinet Cabinet Tops Cabinet Shop Plumb& Tile End Wall 4 Cab. & Utility Set 5 Interior Walls 3 Plumb, Util., Tile 6 End, Side, Drywall & Electrical Side Wall Jig 2B Decking Raw Material Side Wall Jig 7 Side, Drywall, Elec. Roof Ass’y Buffer 8 Marriage, Drywall & Electrical Raw Material Mud Pit Heater 2A Electrical Mud Pit Raw Material 2A Floor Box 9 Roof Set, Drywall & Electrical HVAC Mezzanine Raw Material 10 Rough Roof, Exterior & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 11 Shingle, Siding & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 12 Sofit & Fascia 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish

  9. Future Interior Walls Upper Cabinet Cabinet Tops End Wall Utility Prep. Lower Cabinet 7 End, Side & Mate Wall 5 Cabinet Set, Tile & Utility Set 6 Interior Wall Set Side Wall Jig Side Wall Jig 8 Marriage, Drywall & Electrical Raw Material Plumb 4 Plumb Roof Ass’y Heater 3 Decking Mud Pit Raw Material 9 Roof Set, Drywall & Electrical 2 Floor Box HVAC Mezzanine Raw Material 10 Rough Roof, Exterior & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 11 Shingle, Siding & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 12 Sofit & Fascia 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish

  10. Results • Reduced through-put time 27% • All production within facility • Eliminated NVA protection for outside floors • Eliminated NVA moves • Identified real-time data collection requirements • Started a kaizen project list

  11. Highlights • Lean initiative driven by business objective • Established lean process • Identified root cause • Listened to the data • Workers contributed mightily

  12. Lessons • Lean cannot be forced by one person • Involve employees • Allow team to own the decisions • Lean is a process

  13. Going Forward • Refine our lean process • Conduct kaizen events to improve efficiency in departments • Revise plant layout to convert to double floor stations

  14. Lean Symposium

  15. 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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