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Factory Building Symposium on Lean Production

In a presentation at the Factory Building Symposium on Lean Production, Butch Berlin, Assistant Production Manager at Hi-Tech Housing, highlighted strategies to improve wall production and changeover times. Key changes included optimizing wall build cycles, enhancing workspace organization, and implementing a robust "Five S" program. These adjustments led to significant savings, with annual labor costs reduced by $35,000 and space requirements cut by 1,250 sq. ft. Effective management support and focus on continuous improvement were emphasized as vital for maintaining production efficiency.

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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. Wall Production and Changeover Time Hi-Tech Housing, Inc.,Bristol, INButch BerlinAssistant Production Manager

  3. Hi-Tech Housing

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

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

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

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

  8. 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

  9. 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

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

  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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