Factory Building Symposium on Lean Production

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Factory Building Symposium on Lean Production

• January 29, 2007Austin, Texas

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Four Seasons Housing, Inc.Middlebury, INAustin
Baidas, CEO and President

• Level the Load

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Four Seasons Housing
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Objective Balance the Line

• Eliminate non-value added (NVA) activity
• Reduce cycle time variability
• Station to station
• Floor to floor

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Strategy

• Map product flow
• Analyze data to identify causes of cycle time
  variability
• Implement solutions that reduce NVA and control
  cycle time variability

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Sources of Variation

• Double vs. single floor stations
• Variation in complexity from A to B half

Tactic Convert single floor stations to double
floor stations
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Then
Interior Walls
Upper Cabinet
HVAC Mezzanine
Cabinet Tops
Plumb Tile
Cabinet Shop
Cabinet Shop
Plumb Tile
2A HVAC, H2O, DWV
Raw Material
End Wall
5 Interior Walls
2C Decking
3 Plumb, Util., Floor
4 Cabinet Set
6 End, Side, Drywall Electrical
Side Wall Jig
Raw Material
Side Wall Jig
7 Side, Drywall, Elec.
Roof Assy
8 Marriage, Drywall Electrical
Raw Material
2B Pre-Floor
Mud Pit
Mud Pit
Raw Material
9 Roof Set, Drywall Electrical
Heater
Raw Material
1B Post-Frame
1A Frame
Raw Material
10 Rough Roof, Exterior Interior
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
11 Shingle, Siding Interior
Paint, Dry, Finish
13 Mud, Dry, Prep
Paint, Dry, Finish
13 Mud, Dry, Prep
12 Sofit Fascia
Paint, Dry, Finish
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep
Paint, Dry, Finish
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Now
HVAC Mezzanine
Interior Walls
Upper Cabinet
Cabinet Tops
Cabinet Shop
Plumb Tile
End Wall
4 Cab. Utility Set
3 Plumb, Util., Tile
5 Interior Walls
6 End, Side, Drywall Electrical
Side Wall Jig
2B Decking
Raw Material
Side Wall Jig
7 Side, Drywall, Elec.
Roof Assy
Buffer
8 Marriage, Drywall Electrical
Raw Material
Mud Pit
Heater
2A Electrical
Mud Pit
Raw Material
2A Floor Box
9 Roof Set, Drywall Electrical
HVAC Mezzanine
Raw Material
10 Rough Roof, Exterior Interior
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep
11 Shingle, Siding Interior
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
12 Sofit Fascia
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
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Future
Interior Walls
Upper Cabinet
Cabinet Tops
End Wall
Utility Prep.
Lower Cabinet
7 End, Side Mate Wall
5 Cabinet Set, Tile Utility Set
6 Interior Wall Set
Side Wall Jig
Side Wall Jig
8 Marriage, Drywall Electrical
Raw Material
Plumb
4 Plumb
Roof Assy
Heater
3 Decking
Mud Pit
Raw Material
9 Roof Set, Drywall Electrical
2 Floor Box
HVAC Mezzanine
Raw Material
10 Rough Roof, Exterior Interior
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep
11 Shingle, Siding Interior
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
13 Mud, Dry, Prep
12 Sofit Fascia
13 Mud, Dry, Prep
Paint, Dry, Finish
Paint, Dry, Finish
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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

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Highlights

• Lean initiative driven by business objective
• Established lean process
• Identified root cause
• Listened to the data
• Workers contributed mightily

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Lessons

• Lean cannot be forced by one person
• Involve employees
• Allow team to own the decisions
• Lean is a process

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Going Forward

• Refine our lean process
• Conduct kaizen events to improve efficiency in
  departments
• Revise plant layout to convert to double floor
  stations

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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