Factory Building Symposium on Lean Production

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Factory Building Symposium on Lean Production

• January 29, 2007Austin, Texas

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• Management Commitment

Southern Energy Homes Addison, AL Lamar
Dickerson, Director of Lean Manufacturing
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Southern Estates Plant
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Interior Wall Build
Now
Then

• Material Flow
• Work Space
• Conveyance
• Quality
• Information flow

Organization and new hoist relieve strain and
speed production
Material not close to point of use
Product flow rationalized
No error proofing
Jigs help maintain quality
Confusion leads to production of wrong parts
Racks and labeling system
Congestion slowed work
Visibility across workstation promotes visual
management
Lots of toting
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Results

• Production on target
• Reduced from 9 to 6.5 people
• Re-assigned workers to other departments
• Space reduced by 12
• Wallboard damage reduced 10
• One-time cost of RPI 25,786
• Annual labor savings of 73,200 plus the savings
  of not needing to hire and train 2.5 workers

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Highlights

• Wide range of RPI participants
• All key people present
• Strong support of plant management
• Morale in wall department very high

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Management Commitment

• Dedicated director of lean
• Permit teams to take time
• Invest in the changes
• Take workers seriously
• Senior manager involvement

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Going forward

• Spread lean company-wide
• Management workshop
• Lean teams
• Plants required to conduct lean activities

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Lean Symposium
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Factory Building Symposium on Lean Production

• Manufactured Housing Research Alliance
• Jordan Dentz
• [phone] x13
• jdentz_at_research-alliance.org
• www.mhrahome.org