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Factory Building Symposium on Lean Production

Learn how Palm Harbor Homes implemented lean principles to free up space, generate cash, and improve teamwork in their factory building operations. Discover the strategies used to declutter and optimize production space, resulting in cost savings and improved safety. Gain insights from the Lean Symposium case studies presented on lean manufacturing techniques applied in the context of manufactured housing production.

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Factory Building Symposium on Lean Production

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

  2. Palm Harbor HomesAlbemarle, NCAllen Tucker, Production Manager Clutter to Cash

  3. Palm Harbor Albemarle

  4. 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

  5. Palm Harbor’s Strategy • 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 • Form RPI team • Designate red tag area • Develop red tag process • Implement red tag system Lean principle: written standard operating procedures

  6. 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

  7. 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

  8. Roof Plastic Application

  9. Roof Plastic Then • Small, unstable and awkward work platform • No material staging • Unsafe rolling procedure

  10. 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

  11. 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

  12. Going Forward • “Five S” program • Red tag system • Racks, jigs and fixtures

  13. Lean Symposium

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

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