Enterprise Transformation through Lean Six Sigma Deployment

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Enterprise Transformation through Lean Six Sigma
Deployment
F404 Case Study A Journey of Discovery

• VADM Wally Massenburg, USN (Ret)
• 1 May 2008

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NAVAL AVIATION ENTERPRISE
Requirements/Risk Assessment CEO CHIEF EXECUTIVE
OFFICER
RIGHT FORCE . . .RIGHT READINESS . . . RIGHT
TIME . . .RIGHT COST . . .
Sponsors CFO CHIEF FINANCIAL OFFICER
Providers COO CHIEF OPERATING OFFICER
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OPERATING AS AN ENTERPRISE

• SINGLE PROCESS OWNER
• SINGLE FLEET-DRIVEN METRIC AIRCRAFT UNITS
  READY FOR TASKING AT REDUCED COST (CONTINUES TO
  MATURE)
• VALUES WHAT WE BELIEVE
• FLEET READINESS
• COST-WISE (LESS S)
• TIME ON WING (LESS STUFF)
• SPEED (LESS TIME IN MAINTENANCE)
• PEOPLE (CONTINUOUS IMPROVEMENT)
• THREE MAIN FOCUS AREAS
• READINESS TODAY, TOMORROW, AND FUTURE
• TOTAL FORCE READINESS (PEOPLE DIMENSION)
• COST MANAGEMENT

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THE INSPIRATION
AIRCRAFT
Where did the money go?
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Basis for Process Improvement Lean Six Sigma
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F404 I-Level Consolidation Metrics
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F404 I-Level Consolidation Over-Arching Benefits

• Eliminates I-1 training requirements
• Aligns sea shore duty billet skill sets (I-3
  repairs mirrored at sea ashore)
• Utilizes manpower more efficiently with civilian
  workforce
• Creates local permanent resident experts with
  civilian workforce
• Eliminates high turnover of mechanics
• Reduces lost time due to inexperience
• Reduces infant mortality removals (TOW)
• Reduces production assembly variances
• Increases projected reliability
• Historically depot produced engines consistently
  had higher TOW than I-level sites
• Depot MEFHBR 502 EFH FY00-05
• Five major I-1 activities MEFHBR 398 EFH FY00-05
• All options support CNOs military manpower
  reduction goals

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FLEET-WIDE VISIBILITY
READINESS
FLIGHT HOUR PROGRAM
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OVERARCHING READINESS AND SUSTAINMENT CONCEPT

• Balance Capability and Availability _at_ Reduced
  Cost
• (Fleet Driven Metric)
• Supporting Metrics
• Inventory (People and Stuff)
• Reliability
• Cycle Time Reduction
• Total Cost (All Financial Stovepipes)
• 10 Integrated Logistics Support Elements
• (Where all the cost is borne)

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