Lean Overview

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• Lean Overview
• The Basics
• Presented By Bill Stockstill TMAC
• Panel Members
• Rosina Wittmeyer DRS Infrared Technologies, LP
• Bob Brunett Bell Helicopter Textron
• Mike Navaira Lockheed Martin Aeronautics

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What is TMAC?

• Texas Manufacturing Assistance Center
• Our Mission
• Improve the global competitiveness of Texas
  Manufacturers by applying the appropriate
  techniques and technologies.

TMAC works closely with Manufacturing Supply
Chain to make them more competitive by
providing assistance in appropriate use of
technologies and techniques

• TMAC is part of the MEP System

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TMAC Services

• Management Controls, Systems, and Compliance
• Planning Policy Deployment
• Financial Controls and Measurement Systems
• EPA, OSHA
• QMS, EMS, SMS
• Culture and Workforce Development
• Supervisor and Technical Training
• Teams/Team Facilitation
• Waste and Variation Reduction
• Lean and Six Sigma
• TPM
• EHS
• Facility Design and Relocation
• Technology Application
• ERP, MRP
• Automation Mechanization

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Cycle Time
One of the most noteworthy accomplishments in
keeping the price of Ford products low is the
gradual shortening of the production cycle. The
longer an article is in the process of
manufacture and the more it is moved about, the
greater is its ultimate cost. Henry Ford,
1926
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Mass Production
Material
LEDs
Diodes
Springs
Shipping
Receiving
Warehouse
Warehouse
Storage
Repair
Kitting
Testing
Ship
Value-Added Time

Minutes
Time in Plant

Weeks
ORDER
CASH
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Defining Lean
Lean has been defined in many different ways.
A systematic approach to identifying and
eliminating waste (non-value-added activities)
through continuous improvement by flowing the
product at the pull of the customer in pursuit of
perfection. The MEP Lean Network
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Definition of Value Added

• Value Added
• Any activity that increases the market form or
  function of the product or service. (These are
  things the customer is willing to pay for.)
• Non-Value Added
• Any activity that does not add market form or
  function or is not necessary. (These activities
  should be eliminated, simplified, reduced, or
  integrated.)

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Lean Eliminating the Wastes
Non-Value Added
Value Added

• Defects
• Overproduction
• Waiting / Busy Work
• Non Value Added Processing
• Transportation / Conveyance
• Inventory
• Motion
• Employees Underutilized

Typically 95 of all lead time is non-value added
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Benefits of Lean
Percentage of Benefits Achieved
0 25 50 75 100
Lead Time Reduction
Productivity Increase
WIP Reduction
Quality Improvement
Space Utilization
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Lean Strategic Initiative Elements

• Burning Platform Operational Excellence as Key
  Strategy
• Defined Roles and Responsibilities
• Management Sponsored and Driven
• Mid-Management Fueled
• Grass Roots Implemented
• Wide Spread Orientation
• Formal Launch
• Need for Change
• WIFM
• Management Expectations
• Layoff Policies
• Requires Management System
• Regular Progress Checks
• Communication
• Integrated Measurements
• Recognition and Rewards
• Project Management
• Team Culture
• Proposal System

Lean
6 sigma
Strategic Planning
Work Force Develp
Resource Accounting
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For More Information...
Mark Sessumes [phone] email
sessumes_at_arri.uta.edu Bill Stockstill
[phone] email bstockst_at_arri.uta.edu