Factory Building Symposium on Lean Production

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Factory Building Symposium on Lean Production

• January 29, 2007Austin, Texas

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Palm Harbor HomesAlbemarle, NCAllen Tucker,
Production Manager

• Clutter to Cash

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Palm Harbor Albemarle
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Goal Free Space in the Plant

• Obsolete and damaged material
• Unneeded equipment
• Poor organization of space
• No system to flush items not needed for
  production from production space

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Palm Harbors Strategy

• Form RPI team
• Designate red tag area
• Develop red tag process
• Implement red tag system

• Departments submit lists
• Items moved to red tag area
• Count and value estimates prepared
• Team meets to examine the items and decide their
  fate
• Decision is carried out as soon as possible
• Process repeats weekly

• Allen Tucker, production manager
• Tommy Rogers, special projects manager
• Darrell Story, supervisor of cabinets, doors,
  trim depts.
• Mark Burke, purchasing manager
• Deedy Hatley, assistant purchasing manager
• Doug Eudy, quality assurance manager
• Dalton McCollum, inventory control supervisor

Lean principle written standard operating
procedures
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Results

• Welding, plumbing, ceramic, trim and final areas
  are less cluttered and more organized
• Recovered 7,603 in obsolete molding
• Recovered 1,689 from obsolete ceramic tile
• Recovered 1,760 from obsolete light fixtures
• Total saved to date 21,282

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Highlights

• Using lean to clear space and generate cash
• Team allows fast action
• Keeps purchasing and sales on their toes
• Empowers people
• Increases involvement in lean
• Improves teamwork

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Roof Plastic Application
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Roof Plastic
Then

• Small, unstable and awkward work platform
• No material staging
• Unsafe rolling procedure

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Roof Plastic
Now
Now

• Large stable platform full width of module
• Material staging on platform
• Access for supply from fork truck
• Plastic rolls mounted on spool

Lean principles Five Ss, ergonomics
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Results

• Cost 10,000 in materials and 3,000 in labor
• Safer roof access and application
• Cycle time reduced
• Fewer workers required
• Additional platforms under consideration

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Going Forward

• Five S program
• Red tag system
• Racks, jigs and fixtures

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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