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Factory Building Symposium on Lean Production

Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas . Palm Harbor Homes Albemarle, NC Allen Tucker, Production Manager. Clutter to Cash. Palm Harbor Albemarle. Goal: Free Space in the Plant. Obsolete and damaged material Unneeded equipment

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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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