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Lean Six Sigma Case Study: MRAP

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October 2008 Lean Six Sigma Case Study: MRAP Matt Shapiro, LSS Black Belt Krista Walker, LSS Black Belt Delivering Joint Interoperable Solutions to the Warfighter ... – PowerPoint PPT presentation

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Title: Lean Six Sigma Case Study: MRAP


1
Lean Six Sigma Case Study MRAP
October 2008
Matt Shapiro, LSS Black Belt Krista Walker, LSS
Black Belt

Delivering Joint Interoperable Solutions to the
Warfighter Through Engineering Excellence
Speed to Capability
Rapid Prototyping
Leveraging Technology
2
Why is Lean Six Sigma important?
  • Federal government is pushing LSS
  • Future contracts
  • Just good business

3
Meeting Our Nations Demand Signal
4
Strategic to Tactical
4
5
Initial Surge Exceeded Existing Capacity
  • Suboptimal Flow
  • No Standard Work Areas
  • Suboptimal Line Balance
  • Excess Change over time
  • Suboptimal Standard Work

August 2007
6
Recipe for Success
Team Unification
50 MRAPS Per Day
Lean Six Sigma


Process Improvement Team fully devoted to Lean
Six Sigma activities 1 Lead Program Black Belt 3
Execution Black Belts 6 Green Belts 1 MBB George
Group Coach
7
Lean Six Sigma Line Design
Station 1
Station 2
Point-of-Use Hardware
QA Line Checklist
GFE Kits
POU Storage
GFE Kits
POU Storage
1
5 Hours
5 Hours
4
Final QA Inspection
GFE Carts
2
Visual Line Analysis
Visual Line Analysis
TAKT Boards
3
Index Build Pace 5 Hours Per Station
8
Lean Six Sigma Status
  • Total Projects Identified 57
  • 7 Projects in progress
  • 44 Completed
  • 6 future events

Capacity exceeds demand
  • Achieved 50 Integrated C4ISR Per day 5 Dec 2008
  • 3719 Completed 31 JAN 2008
  • 10,000 Competed 21 AUG 2008

9
Lessons Learned
  • Senior Management Engagement is Key
  • Inclusion of Subject Matter Expert (Worker) is
    critical
  • Quick results Challenge current conventions
  • Standardized Work Flow is Critical

10
Questions?
January 2008 (50 per day)
August 2007 (5 per day)
Transformation
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