low tech high touch solutions

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Low Tech-High Touch Visual Process Management in ETO (Engineer to Order) Environment Pratik Desai Lean Systems & Industrial Engineering Pauline Fowler Senior Director of Engineering Multiplexer Bus. Unit

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Page 1: Low tech High touch solutions

Low Tech-High Touch Visual Process Management

in ETO (Engineer to Order) Environment

Pratik Desai

Lean Systems &

Industrial Engineering

Pauline Fowler

Senior Director of Engineering

Multiplexer Bus. Unit

Page 2: Low tech High touch solutions

COM DEV International Overview

• In operation since 1974

• 2013 Revenue: $215.5 M Cdn

• Employees: 1204

• Satellite contracts to date: 811

• Public Ownership: TSX-CDV

• World’s most prolific supplier of satellite

equipment –

With products and subsystems on more

than 800 satellites and counting.

Cambridge, ON Aylesbury, UK Ottawa, ON El Segundo, CA Cambridge, ON

2

48%

35%

17%

2013 Revenue Split

Commercial Space Civil Space

Military Space

>95% of all TV Channels Broadcast in N America Pass Through our Equipment

Page 3: Low tech High touch solutions

Customers

3

Since 1995

Since 1982

Since 1975

Since 1975

Since 2004

Since 1984

Since 1997

Since 1990

Since 1982

Since 1990

Since 1979

Since 1987

Since 1995

Since 2002

Since 1987

Since 1982

Since 1985

Since 1985

Since 1998

Relationships with all satellite primes – lasting decades.

Page 4: Low tech High touch solutions

4

Product and Processes

Simple to Complex Assemblies for Commercial and Military Space Application

Variety of Processes to convert Customer Specification to

Space Qualified Product

Page 5: Low tech High touch solutions

Top Level Value Stream Map

Contract Award

Bid Handover

Project Kickoff Notice

Schedule and Status

Design Approvals

5

Program Management

Production

Marketing & Contracts

Engineering Supply Chain

Build Approvals

This

Presentation

Focus

This

Presentation

Focus

Page 6: Low tech High touch solutions

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Complexities in ETO Environment

Our Business is Rocket Science but Lean is not!

Our customer Loves variation and Unique requirements

Change of Scope is normal practice

Our process starts when even customer is not sure what they

want but they always want cheaper, faster and better

Customer involvement and approvals at each stage of process

Detail documentation for traceability control

100% testing on components in simulated Space environment

Page 7: Low tech High touch solutions

7

Production All in One Board Engineering Project Status Tracking

2

Visual Management Solutions

1 Visual Process Management Implementations

Page 8: Low tech High touch solutions

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NO Defined Process

FIRE FIGHTING

Information Hidden in Computers

and in Peoples mind

Silos

Variation in information

Lack of Standardization

Variation and Hidden information contributes to Complexity, Rework,

Waiting and Over processing

Engineering Project Status Tracking- Before

Page 9: Low tech High touch solutions

9

Week 1 to 24 Normal Engineering Process Lead Time (most programs)

Project Kick Off Date Project Kickoff is the Time ZERO (T0) for Engineering Process

Project Lead Engineer Name of Lead Project Engineer. Lead Engineer controls Cost, Schedule of Engineering Activities

Project Tile One Tile for Each Project. Tile moves one cell right every week.

Project Status Tracking- Now

Low Tech – High Touch Solution

Page 10: Low tech High touch solutions

10

Status Tracking Board: How it Works

• Standard Lead time : 24 Weeks

• Tile with Red Remarks: Issues(Need Support)

• Standard Template

• New Tile for Each Project

• Tile Moves one cell each week

• Blank Tile= Good News(No Issues)

Power of Visual Management

Page 11: Low tech High touch solutions

11

Weekly Review Meeting @ White Board

WHO:

Lead Engineers, Program Managers, Engineering Management

What:

Update status

Review Status and Discuss support Requirements

Actions if required

5’ x 2 min Principle

Page 12: Low tech High touch solutions

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Page 13: Low tech High touch solutions

13

How we did it

Standard template

defined in Future

State VSM

Prototype model

of whiteboard

created to prove

concept

Idea to use

standard template

for visual status

monitoring

Engineering Team

Involving employees and implementing feedback

Process initiated

and practiced on

temporary board.

Striving towards

a self sustaining

Process

Engaging people + Developing behaviors = Sustainment

4 Months from Concept to Implementation 34 months

Page 14: Low tech High touch solutions

14

BENEFITS

Coaching and

Mentoring

Eliminated

Silos

Issues

Highlighted

Status

Tracking

Unique Gemba Walk eh!

Page 15: Low tech High touch solutions

15

Learning Review- 1

Your Business can be a Rocket Science but Lean is not is not!

Low tech High touch solutions

Variation and Hidden information contributes to Complexity, Rework,

Waiting and Over processing

5’ x 2 min Principle

Engaging people + Developing behaviors = Sustainment

Gemba Walk

Page 16: Low tech High touch solutions

16

Production All in One Board Engineering Project Status Tracking

2

Visual Management Solutions

1 Visual Process Management Implementations

Page 17: Low tech High touch solutions

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Production Process Before

Shift start time ≠ Work start time

Problems discussed in

Conf. rooms ≠ actual @ Gemba

Who is working on this JOB? Go ask one by one

Need Support? Go and Chase them down

Need Information quickly? Good Luck

Material (Jobs) travels like

Process qualified for all categories of Waste

Page 18: Low tech High touch solutions

18

Production Process NOW

Common source and centrally located information … NO MORE Searching

2 Week Schedule posted weekly

Operators Daily highlight status

Assignments for all shifts

Jobs on Hold –Need support

Jobs not received from Previous department

+/- days to need date

Page 19: Low tech High touch solutions

19

How It Works

BLUE

Two Weeks Schedule – Printed and Posted Weekly

TECH Name Operator names(All shifts) assigned using magnet to each job.

RED

SUPPORT DEPT NAME

Jobs in Queue and not assigned

Jobs not moving and need support

Jobs did not received from previous department as per schedule

Simple solutions are portable and easy to steal with pride

Page 20: Low tech High touch solutions

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Daily Shift Change Over

Current Shift Employees Next Shift Employees

Update status of their jobs.

Put Red magnets if needed

Info sharing with operator

from next shift

Check assignments and Priority

Info sharing with operator from

next shift

Put Red magnets if needed during

the shifts

Picture

Process own by employees

Page 21: Low tech High touch solutions

21

Daily 8:30 standing meeting @ Gemba

Engineering

QC/QE/PAPM

Program

Management

Office 10 Min Stand-up

meeting @

Gemba

Resolution within

2~3 hours

Area Reps.

Communicate

issues within their

department

Focus on Uninterrupted flow of material

Page 22: Low tech High touch solutions

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Video

Page 23: Low tech High touch solutions

Benefits

23

Waste Elimination

Waiting

Rework

Complexity

Over processing

Inventory

All information in one location and readily available for any one at any time.

Process Simplification and Reduction in Waste leads to Cost and Lead time

reduction.

Employee involvement and Engagement : Building Human capital

Transition from always reactive to proactive actions

From Fire Fighting to Proactive and Predictive Environment

Page 24: Low tech High touch solutions

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Learning Review- 2

Process complexity -form of a waste category

Common source and centrally located information … NO MORE Searching

Simple solutions are portable and easy to steal with pride

Focus on Uninterrupted flow of material

From fire fighting to proactive and predictive environment by Visual

Management

Your Business can be a Rocket Science but Lean is not is not!

Low tech High touch solutions

Variation and Hidden information contributes to Complexity, Rework, Waiting and Over processing

5’ x 2 min Principle

Engaging people + Developing behaviors = Sustainment

Gemba Walk

Page 25: Low tech High touch solutions

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Conclusion

If we Can Do IT, So can you.

Think Low Tech- High Touch Visual Solutions

Select tools and methods and modify as required

Start slow - move fast

Involvement and buy-in of all employees

Page 26: Low tech High touch solutions

Thank You! To sustain lean journey, it is essential to keep asking questions. We welcome any

feedback or recommendations.

Please complete the session survey at: AMESurvey.org

Session Code: ThP/10

Low Tech-High Touch Visual Process Management

in ETO (Engineer to Order) Environment

Pratik Desai

Pauline Fowler

COM DEV Ltd.

[email protected]

[email protected]