Factory Building Symposium on Lean Production

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Factory Building Symposium on Lean Production

• January 29, 2007Austin, Texas

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• Finding the Right Fit

Clayton Homes Andersonville, TN
Brent Crabtree, Lean Advocate
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Clayton Appalachia
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Approach

• Choose small scale initial events to ensure
  success and refine the process and team
• Thorough and comprehensive execution

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Door Build Problems
Now
Then

• Damage
• Congestion
• Productivity

Piles of WIP and excessive conveyance resulted in
damaged doors
One-third the WIP
Clear traffic aisles
Batch and queue
Continuous flow work cell with no WIP between
WIP over flowed into traffic aisles
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Results
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Final Finish
Then
Now

• Productivity

Materials far from point of need, leading to
excessive motion and conveyance
Eliminated excess transport and removed unneeded
items
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Results
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Highlights

• Always room to improve
• Can make the workplace better
• Team members enthusiasm
• Management commitment
• Data gathering and analysis

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Going forward

• Incorporate lessons learned
• Broadcast successes
• Tackle bigger projects
• Developing lean training program
• Rolling out lean to additional plants
• Change of mindset

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Lean Symposium
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Factory Building Symposium on Lean Production

• Manufactured Housing Research Alliance
• Jordan Dentz
• [phone] x13
• jdentz_at_research-alliance.org
• www.mhrahome.org