completed & current lss projects

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Completed & Current Lean/Six Sigma Projects

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Page 1: Completed & Current LSS Projects

Completed & Current Lean/Six Sigma Projects

Page 2: Completed & Current LSS Projects

Continuous Improvement Projects

SMT Machine Setup Reduction, 1997 - 2001

Surface Mount machines were experiencing all day setups. The goal was to reduce setup time to 30 minutes. The largest percentage (28%) was due to the machine programmer’s first pass yield. At the beginning of 2001 the downtime due to the machine program was at a steady 3% which was attributable to new parts in a prototype environment.

1) Standardized setup reports – Standard Work

2) Off-line feeder setups – SMED

3) Created feedback loop for part changes made on machine – Standard Work

4) Improved programmers standard work flow to make person available to support machine programs during setup – Waste Reduction, Standard Work

5) Created standard locations on machines for high repeat components – Standard Work, SMED

6) Networked machines to standard part library – Standard Work

Page 3: Completed & Current LSS Projects

Continuous Improvement Projects

Factory Lean Six Sigma Integration, 2002 – PresentBegan using Boeing’s Lean Manufacturing Assessment (LMA) to measure maturity level of work centers and the factory with most of the focus on the work centers. In 2005 we began to shift to a factory view of waste reduction and flow improvement by utilizing production lines that move to takt time.

1) Work center measurement system and goals for unit cost reduction.2) Rebalanced final work cell in final assembly and created standard flow –

Waste Reduction, Standard Work3) Fully documented setup of three-piece rings to five meter diameter

composite shell – Standard Work4) Lean Six Sigma Green Belt training development and deployment at all

sites.5) Improvement of top quality failures in work centers – Waste Reduction6) Work center Value Stream Map development in Decatur factory.7) Enterprise Value Stream Map development, Engineering, Contracts,

Supply Chain, Production Operations, and Launch Operations.8) Team metric development using data from MES and ERP.

Page 4: Completed & Current LSS Projects

Continuous Improvement Projects

Factory Lean Six Sigma Integration, Present and Future Perfect Product Delivery - A way of thinking about what you do and

how you align with your customer’s expectations. This connects Lean, Six Sigma, TOC, Process Based Management, TQM, and Breakthrough Process Redesign together in a method to achieve unseen levels of customer satisfaction. This answers how to deliver all products in a manner that completely satisfies the needs of the downstream customer.

Lean Six Sigma Champion training – Now I have all these Green Belts and Black Belts, what do I do with them? The answer is easy, enable and empower them to help you completely satisfy the needs of your downstream customer.

MBA – What else would a Black Belt need?