Factory Building Symposium on Lean Production

Factory Building Symposium on Lean

Production

January 29, 2007Austin, Texas

Finding the Right Fit

Clayton HomesAndersonville, TN

Brent Crabtree, Lean Advocate

Clayton Appalachia

Started: 1994 Location: Andersonville,

TN Home types: HUD Code Price point : Moderate Design: No

customization Production: 10 to18

floors/day Market area: Mid-eastern

states

Approach

Choose small scale initial events to ensure success and refine the process and team

Thorough and comprehensive execution

Door Build: Problems

Damage Congestion Productivity

WorkstationsWIP

Piles of WIP and excessive conveyance resulted in Piles of WIP and excessive conveyance resulted in damaged doorsdamaged doors

One-third the WIPOne-third the WIPWIP over flowed into traffic aislesWIP over flowed into traffic aislesClear traffic aislesClear traffic aislesBatch and queueBatch and queueContinuous flow work cell with no WIP betweenContinuous flow work cell with no WIP between

Then Now

Workstations

Results

Issue Before After Change

Space 960 sq. ft. 800 sq. ft. 16% less

Raw doors in area

269 doors 151 Doors 43% less

WIP between processes

3 houses of doors 0 100% less

Completed door inventory

3 houses of doors2 houses of

doors33% less

Flow time 40 hours 20.4 hours 50% less

Productivity with 2 team members

65 doors/day 200+ doors/day 300% more

Final Finish

ProductivityThen Now

Materials far from point of need, leading to excessive motion Materials far from point of need, leading to excessive motion and conveyanceand conveyance

Eliminated excess transport and removed unneeded itemsEliminated excess transport and removed unneeded items

Results

Per house Before

After Change

Walking 1.3 mi

0.6 mi

54% less

Trips 22 13 41% less

Space n/a n/a 615 sf less

Time 40 min

15 min

63% less

Highlights Always room to

improve Can make the

workplace better Team members

enthusiasm Management

commitment Data gathering and

analysis

Going forward

Incorporate lessons learned

Broadcast successes Tackle bigger projects Developing lean

training program Rolling out lean to

additional plants Change of mindset

Lean Symposium

Manufactured Housing Research AllianceJordan Dentz

(212) 496-0900 x13jdentz@research-alliance.org

www.mhrahome.org

Factory Building Symposium on Lean

Production