Factory Building Symposium on Lean Production

1. Factory Building Symposium on Lean Production January 29, 2007Austin, Texas

2. Four Seasons Housing, Inc.Middlebury, INAustin Baidas, CEO and President Level the Load

3. Four Seasons Housing

4. Objective: Balance the Line • Eliminate non-value added (NVA) activity • Reduce cycle time variability • Station to station • Floor to floor

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

6. 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

7. Then Interior Walls Upper Cabinet HVAC Mezzanine Cabinet Tops CabinetShop Plumb & Tile Cabinet Shop Plumb& Tile 2A HVAC, H2O, DWV Raw Material End Wall 5 Interior Walls 4 Cabinet Set 3 Plumb, Util., Floor 2C Decking 6 End, Side, Drywall & Electrical Side Wall Jig Raw Material Side Wall Jig 7 Side, Drywall, Elec. Roof Ass’y 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 Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish 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 Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish

8. Now HVAC Mezzanine Interior Walls Upper Cabinet Cabinet Tops Cabinet Shop Plumb& Tile End Wall 4 Cab. & Utility Set 5 Interior Walls 3 Plumb, Util., Tile 6 End, Side, Drywall & Electrical Side Wall Jig 2B Decking Raw Material Side Wall Jig 7 Side, Drywall, Elec. Roof Ass’y 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 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 11 Shingle, Siding & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 12 Sofit & Fascia 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish

9. 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 Ass’y Heater 3 Decking Mud Pit Raw Material 9 Roof Set, Drywall & Electrical 2 Floor Box HVAC Mezzanine Raw Material 10 Rough Roof, Exterior & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 11 Shingle, Siding & Interior 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish 12 Sofit & Fascia 13 Mud, Dry, Prep Paint, Dry, Finish Paint, Dry, Finish

10. 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

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

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

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

14. Lean Symposium

15. Factory Building Symposium on Lean Production Manufactured Housing Research Alliance Jordan Dentz (212) 496-0900 x13 jdentz@research-alliance.org www.mhrahome.org