Moonshine Process at Boeing – Focus on Function, Flow & Equipment

1. Moonshine Processat Boeing – Focus on Function, Flow & Equipment Earl S. Robinson Jr Senior Lean Practitioner Boeing Commercial Airplanes SLM800137702-01.ppt

2. Moonshine Process at Boeing • What we will discuss today • A high-level look at the role of Lean+ at The Boeing Company • A definition of Moonshine at Boeing • Examine the steps of the Moonshine process • Share some examples of Moonshine activities • We will learn more about some of the steps by trying them • Have a dialogue about Moonshine and improvement

3. Lean+ and the Big Picture Boeing is pursuing four initiatives to accelerate long-term growth and productivity gains across the enterprise: • Lean+ • Internal Services Productivity • Global Sourcing • Development Process Excellence Lean+ is the foundational initiative and the key to success with the others. It is the one overarching continuous improvement approach at Boeing and aligns with Lean, Employee Involvement & Engagement, Six Sigma, Process Management, Project Management and Theory of Constraints, among others.

4. Continue to invest in market driving products, features and services that improve our competitiveness Quality, Flow, Stability Growth and Productivity - Six Focus Areas Working together to provide preferred products and services that enable our customers to be more successful! Creating Value for All!

5. Moonshine Process at Boeing • Moonshine refers to an improvement activity that is formally known as the “Production Preparation Process” (3P) • Purpose • Improve the flow of a production process by developing production engineering redesigns, right sized equipment and processes that focus on the transformational steps • To “re-engineer” the process • Considered an advanced Lean+ technique • Incremental improvement • Breakthrough improvement, redesign

6. What is Moonshine and it’s Relationship to Lean? Moonshine Process at Boeing • The term “Moonshine” used at Boeing is something we learned from our Lean teachers. They explained it as work that was done at night, away from normal process work, where those who do the work can put their improvement ideas into concepts and prototypes, presenting them to management when they had a completed idea. • In the US the term is derived from the days when individuals illegally made their own liquor during Prohibition. These individuals would "borrow" ideas and test each other's liquor to see what tasted the best and then adopt the best methods • Both definitions are similar. They use the ideas of people familiar with the product or process, use inexpensive material or anything they could find to make their own equipment. The production activity was done under the cover of night (or away from other processes). The best ideas from those making the product were/are tried (simulated) and the best methods are adopted.

7. What is Moonshine and it’s Relationship to Lean? Moonshine Process at Boeing • Simulation is the essence of Moonshine. Moonshine as we know it means to "trystorm (simulate)" and "spend no money" to do what it takes to get the job done right. It is not to condone illegal or unsafe activity. • During 3P (Production Preparation Process) workshops, concept simulation is introduced after 7 Ways have been developed and down-selected to two or three ideas. Moonshine develops these ideas into physical models that are then used for production simulations. During the simulations, the models are continually evaluated and refined until a superior design proposal emerges • After the product/process concept proposal from the 3P is complete the proposal must be tested to meet safety and production requirements and be incorporated into standard work or operations.

8. Moonshine Process at Boeing • The steps of 3P • Define the function, theme and scope • Use keywords to define the function • Find examples of the keywords in Nature • Examine what’s happened, sketch and post examples • Sketch the background and conditions • Combine ideas and create sketches of them; think of at least seven ways • Select the best proposals • Construct prototypes; continue “moonshining”, or innovating • Conduct simulations • Gather and evaluate data; keep moonshining • Review the process with the customer to select the top design

9. Process Change/Relocation New Product Chronic Problem Areas Major Production Rate Change Existing plan does not meet performance metrics Product Design Change Business Case New Process 3P Steps • Implementation: • Flow lines & feeders • Poka-Yoke • Standard Work • Equipment/Tool Fabrication Training Final Process-at-a Glance Fishbone, Process Flows Production Preparation Process Trials & Simulations Process Evaluation 7 Ways Sketches

10. Moonshine Process at Boeing

11. Moonshine Process at Boeing3P Simulation Exercise

12. Moonshine Process at Boeing3P Simulation Exercise

13. Moonshine Process at Boeing3P Simulation Exercise

14. Kaikaku Kaikaku Rate with AIW’s alone Moonshine Process at Boeing

15. Moonshine Process at Boeing • How Do We Accomplish Moonshine at Boeing? • Sensei’s • Certified 3P Practitioners • Management Sponsorship of Projects • Creation of Moonshine Shops • Link projects to business goals, safety for employees, competitive advantage • Creative Thinkers, cross functional team members • Place to conduct Moonshine Projects (equipment, materials, time) • Moonshine Shops • Creation Shop • Innovation centers

16. Moonshine Process at Boeing • Benefits • Right-sized assets • High-quality products • Standard, reliable methods • Dramatic reductions in cost, inventory and lead time • Improved quality • Key deliverables • A simulation of the improved process • An implementation plan • An equipment development plan • Resource requirements • Implementation timeline • A right-sized flowing production system

17. Moonshine Process at BoeingExamples Bracket Chaku Chaku Line

18. Moonshine Process at BoeingExamples Blanking Press withQuick-Change Blanking Tool Material FIFO Device

19. Moonshine Process at BoeingExamples Right-sizedPaint Booth and Dryer AssemblySeal Cure

20. Moonshine Process at BoeingExamples Hydraulic Tube Net Trim Stowbin NC Router

21. Moonshine Process at BoeingExamples “Tugbots” Vacuum Form Hood

22. Right Sized Equipment

23. Moonshine Process at BoeingMoonshine War Competition An annual event where teams compete using the 3P approach to develop solutions to actual workplace efficiency and safety issues. Three teams compete on one of up to seven projects. Prizes are awarded for each project, and a Grand Prize is awarded to the team judged to have developed the best overall solution using the moonshine process.

24. Moonshine Process at BoeingMoonshine War Solutions Stow Bin RailAuto-Deburr Wing HeliumPressure TestDoors

25. Moonshine Process at BoeingReview • The steps of 3P • Define the function, theme and scope • Use keywords to define the function • Find examples of the keywords in Nature • Examine what’s happened, sketch and post examples • Sketch the background and conditions • Combine ideas and create sketches of them; think of at least seven ways • Select the best proposals • Construct prototypes; continue “moonshining”, or innovating • Conduct simulations • Gather and evaluate data; keep moonshining • Review the process with the customer to select the top design

26. Moonshine Process at Boeing Questions?