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Factory Building Symposium on Lean Production

Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas. Chelsea Modular Homes Marlboro, NY Kenneth Hutchings, Lean/Safety Manager. Leveraging Lean. Chelsea Modular Homes. Spackling: Problem. Value stream mapping identified in framing

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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. Chelsea Modular HomesMarlboro, NYKenneth Hutchings,Lean/Safety Manager Leveraging Lean

  3. Chelsea Modular Homes

  4. Spackling: Problem • Value stream mapping identified in framing • Initial RPIs met with limited sustainable successes • Targeted spackling • Poor quality at inspection

  5. Spackling: Causes • Lack of cross-departmental coordination and cooperation • Teams not taking responsibility for work quality • Pervasive “not my job” attitude • Process and product issues not addressed

  6. RPI process • Kenneth Hutchings, lean manager (leader) • Santos Laboy, touch-up crew • Miguel Lora, sidewalls • Randy McGee, mid-line supervisor • Bryon Sharoh, yard supervisor • Dennis Veseley, spackling group leader • Form RPI team • Meet half days for a week • Divided time between plant conference room • Conclude with presentation to management • Team members take responsibility

  7. Changes • Process changes • Product changes • Equipment improvements • New work rules • Standardize work • Organizational changes Lean principles: The “5 why’s,” stop and fix, standardized work

  8. Results • Defects/rework cut by 85% • Fewer touch-up workers needed • QC spends less time on drywall • Results visible to entire plant

  9. Highlights • No-cost changes • Workers understand production as a system • Improved morale • Lean is forcing Chelsea to confront critical issues • Lean providing a forum for management to converse with workers • Lean tapping into worker commitment to the company

  10. Going forward • Regular major RPI events • Frequent smaller 5S events

  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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