factory building symposium on lean production
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Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas . Management Commitment. Southern Energy Homes Addison, AL Lamar Dickerson, Director of Lean Manufacturing. Southern Estates Plant. Interior Wall Build. Now. Then. Material Flow Work Space Conveyance - PowerPoint PPT PresentationTRANSCRIPT
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Factory Building Symposium on Lean
Production
January 29, 2007Austin, Texas
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Management Commitment
Southern Energy HomesAddison, ALLamar Dickerson, Director of Lean Manufacturing
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Southern Estates Plant Started: 1982 Location: Addison, AL Home type(s): HUD Code Price point: Moderate Design: Some
customization Production: 5 to 6
floors/day Market area: Southeast US
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Material Flow Work Space Conveyance Quality Information flow
Organization and new hoist relieve strain and speed productionOrganization and new hoist relieve strain and speed productionMaterial not close to point of useMaterial not close to point of useProduct flow rationalizedProduct flow rationalizedNo error proofingNo error proofingJigs help maintain qualityJigs help maintain qualityConfusion leads to production of wrong partsConfusion leads to production of wrong partsRacks and labeling systemRacks and labeling system
Interior Wall Build
Congestion slowed workCongestion slowed workVisibility across workstation promotes visual managementVisibility across workstation promotes visual managementLots of totingLots of toting
Then Now
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Results Production on target Reduced from 9 to 6.5 people Re-assigned workers to other departments Space reduced by 12% Wallboard damage reduced 10% One-time cost of RPI: $25,786 Annual labor savings of $73,200 plus the
savings of not needing to hire and train 2.5 workers
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Highlights Wide range of RPI
participants All key people present Strong support of plant
management Morale in wall
department very high
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Management Commitment Dedicated director of
lean Permit teams to take
time Invest in the changes Take workers
seriously Senior manager
involvement
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Going forward Spread lean
company-wide Management
workshop Lean teams Plants required to
conduct lean activities
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Lean Symposium
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Manufactured Housing Research AllianceJordan Dentz
(212) 496-0900 [email protected]
www.mhrahome.org
Factory Building Symposium on Lean
Production