factory building symposium on lean production
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Factory Building Symposium on Lean
Production
January 29, 2007Austin, Texas
Four Seasons Housing, Inc.Middlebury, IN
Austin Baidas, CEO and President
Level the Load
Four Seasons Housing Started: 1994 Location: Middlebury, IN Home type(s): Primarily HUD
Code Price point: Moderate Design: Limited
customization Production: 10 floors/day Market area: Northern US
Objective: Balance the Line Eliminate non-value
added (NVA) activity Reduce cycle time
variability› Station to station› Floor to floor
Strategy1. Map product flow2. Analyze data to
identify causes of cycle time variability
3. Implement solutions that reduce NVA and control cycle time variability
Sources of Variation Double vs. single floor
stations Variation in
complexity from A to B half
Tactic: Convert single Tactic: Convert single floor stations to double floor stations to double
floor stationsfloor stations
Then
Raw Material
Raw Material
Raw Material
Roof Ass’y
Raw Material
Mud Pit
Raw Material
Side Wall Jig
Side Wall Jig
End Wall
Plumb & Tile
Mud Pit
Raw Material
5 Interior Walls
1A Frame
1B Post-Frame
2B Pre-Floor
2A HVAC, H2O, DWV
2C Decking 3 Plumb, Util., Floor 4 Cabinet Set
6 End, Side, Drywall & Electrical
7 Side, Drywall, Elec.
8 Marriage, Drywall & Electrical
9 Roof Set, Drywall
& Electrical
10 Rough Roof,
Exterior & Interior
11 Shingle, Siding
& Interior
12 Sofit & Fascia
13 Mud, Dry, Prep
13 Mud, Dry, Prep
13 Mud, Dry, Prep
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Heater
Cabinet Shop
Interior Walls
Cab
inet
Top
s Upper Cabinet
Cabinet Shop
Plu
mb
& T
ile
HVAC Mezzanine
NowInterior Walls
Cab
inet
Top
s Upper Cabinet
Raw Material
Raw Material
Roof Ass’y
Raw Material
Mud Pit
Side Wall Jig
Side Wall Jig
End Wall
Mud Pit
HVAC Mezzanine
Cabinet Shop
Plu
mb
& T
ile
HVAC Mezzanine
2B Decking
3 Plumb, Util., Tile 5 Interior Walls
6 End, Side, Drywall & Electrical
7 Side, Drywall, Elec.
8 Marriage, Drywall & Electrical
9 Roof Set, Drywall
& Electrical
10 Rough Roof,
Exterior & Interior
11 Shingle, Siding
& Interior
12 Sofit & Fascia
Paint, Dry, Finish
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
2A Floor Box
Heater
Raw Material
4 Cab. & Utility Set
Buffer
2A Electrical
13 Mud, Dry, Prep
13 Mud, Dry, Prep
Future
Raw Material
HVAC MezzanineRaw Material
Roof Ass’y
Mud Pit
Raw Material
Side Wall Jig
Side Wall Jig
End Wall
3 DeckingHeater
8 Marriage, Drywall & Electrical
9 Roof Set, Drywall
& Electrical
11 Shingle, Siding
& Interior
12 Sofit & Fascia
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish13 Mud, Dry, Prep
13 Mud, Dry, Prep
13 Mud, Dry, Prep
2 Floor Box
4 Plumb
Interior Walls
Cab
inet
Top
s
Upper Cabinet
Lower Cabinet Util
ity
Pre
p.
Plu
mb
6 Interior Wall Set 7 End, Side & Mate Wall
5 Cabinet Set, Tile
& Utility Set
10 Rough Roof,
Exterior & Interior
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
Highlights Lean initiative driven by business objective Established lean process Identified root cause Listened to the data Workers contributed mightily
Lessons Lean cannot be forced by one person Involve employees Allow team to own the decisions Lean is a process
Going Forward Refine our lean
process Conduct kaizen
events to improve efficiency in departments
Revise plant layout to convert to double floor stations
Lean Symposium
Manufactured Housing Research AllianceJordan Dentz
(212) 496-0900 x13jdentz@research-alliance.org
www.mhrahome.org
Factory Building Symposium on Lean
Production
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