Using Project                                    Roberta Jones                                                      Integr...
Agenda       • Who we are       • Where we started       • How was it organized?       • What is a Lean Manufacturing Asse...
Who are we    • Boeing 737 Commercial Delivery Center, King County International      Airport, Seattle, WA    • Pre-flight...
Who we are                   • Mechanics                   • Quality Inspectors                   • Engineering           ...
Where we started    •    First Lean Manufacturing Assessment (LMA) 2003    •    No Lean Practitioners    •    No Project M...
How was it organized?    • Viewed as a project    • Distinct start and end    • Unique, one off          Every year shoul...
What is a Lean Manufacturing Assessment    (LMA)    • The LMA measures progression from a traditional company to a      Le...
Who was involved    • Built an owners matrix          The owners matrix provided contacts vertically and horizontally in ...
Lessons Learned      What do you get when you look at your products and       processes with a critical eye?      • Formal...
Project Completion Report                   • Important because it leaves a trail for the next PM to look at              ...
Delivering Results      • What went right            We completed the project one month early            The quality of ...
Future Planning           • Leadership                 The Vision must be SMART                  − Specific, Measurable, ...
Future Planning continued                   • Inventory / Supply                         Right size delivery method      ...
2010 Business Plan       We are using the results from the assessment to build our        business plan       • We include...
Summary                   Back to basics                   •    Scope Statement                   •    Stakeholders       ...
Lean Manufacturing Lessons LearnedCopyright © 2010 Boeing. All rights reserved.
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  1. 1. Using Project Roberta Jones Integration Project Manager Management 737 Delivery Center Tools to Improve February 9, 2010BOEING is a trademark of Boeing Management Company.Copyright © 2009 Boeing. All rights reserved.Copyright © 2010 Boeing. All rights reserved. Used with Permission
  2. 2. Agenda • Who we are • Where we started • How was it organized? • What is a Lean Manufacturing Assessment? • Who was involved? • Lessons Learned • Project Completion Report • Delivering Results • Future Planning • SummaryCopyright © 2010 Boeing. All rights reserved.
  3. 3. Who are we • Boeing 737 Commercial Delivery Center, King County International Airport, Seattle, WA • Pre-flight at Clayton Scott Field , Renton, WA • Boeing Commercial Airplanes Paint Operations, Seattle, WA Boeing Copyright photoCopyright © 2010 Boeing. All rights reserved.
  4. 4. Who we are • Mechanics • Quality Inspectors • Engineering  Liaison Engineers  Industrial Engineers • Painters • Material Support • Customer Support • Project Management Office • And numerous othersCopyright © 2010 Boeing. All rights reserved.
  5. 5. Where we started • First Lean Manufacturing Assessment (LMA) 2003 • No Lean Practitioners • No Project Manager • No Plan • No follow through • How was this time going to be different?Copyright © 2010 Boeing. All rights reserved.
  6. 6. How was it organized? • Viewed as a project • Distinct start and end • Unique, one off  Every year should be different if you have improved on the opportunities from the year before • Started with a timeline • Built a rough work breakdown structure  Used the history from other areas • Assigned resources  The people most familiar with the processes gathered the data • Began training sessions  Very few of us had done this before  Used tribal knowledge from other areasCopyright © 2010 Boeing. All rights reserved.
  7. 7. What is a Lean Manufacturing Assessment (LMA) • The LMA measures progression from a traditional company to a Lean production system • Scores range from 1, a traditional company, to 5, a Lean benchmark company • Our areas were scored on 7 elements of improvement  Leadership  Factory organization  Teams and empowerment  Inventory and supply  Manufacturing processes  Continuous improvement  Workplace culture • Several on-line tools available – search for Lean Manufacturing Assessment on the webCopyright © 2010 Boeing. All rights reserved.
  8. 8. Who was involved • Built an owners matrix  The owners matrix provided contacts vertically and horizontally in all categories LMA LMA Section LMA Section LMA Section LMA Section LMA Section LMA Section LMA Sponsor: Leadership Factory Empowerme Inventory & Manufacturing Continuous Section Managers Owner: Organization nt / Teams Supply Processes Improvement Workforce Name Name Owner: Owner: Owner: Owner: Owner: Culture Project Name Name Name Name Name Owner: Manager: Name Name Customer Leaders Leaders Leaders Leaders Leaders Leaders Leaders Delivery name name name name name name name Center: Lean Practitioner Pre-Flight: Leaders Leaders Leaders Leaders Leaders Leaders Leaders Lean name name name name name name name Practitioner Paint: Lean Leaders Leaders Leaders Leaders Leaders Leaders Leaders Practitioner name name name name name name nameCopyright © 2010 Boeing. All rights reserved.
  9. 9. Lessons Learned What do you get when you look at your products and processes with a critical eye? • Formalized the scope of the project • Clearly defined the expectations • Include a Quality Plan  This year we will have an idea what the assessors are measuring • Create a communication Plan • Will use a change Management Plan • Clarify the roles and responsibilities • Using off shift personnel didn’t offer engagementCopyright © 2010 Boeing. All rights reserved.
  10. 10. Project Completion Report • Important because it leaves a trail for the next PM to look at • Comprehensive in nature • Includes a Project Profile, Deliverable list, and Solution Characteristics • Project Evaluation  Scope Management  Time Management  Performance to Master Plan  Performance to Detail Plan  Communication Plan  Overall Strategy and Approach  Methodology − This is where I set the Responsibility, Accountability and Authority (RAA’s) for the team membersCopyright © 2010 Boeing. All rights reserved.
  11. 11. Delivering Results • What went right  We completed the project one month early  The quality of the data collected was very high  We had no need to scramble at the end for more data  There was an appropriate number of resources assigned to the project  All stakeholders had transparent information transfer • What were some issues  We were going to assess Engineering at the same time, but found we didn’t have the resources  Most of the Section Owners and Sub-section Leaders were management  Need to understand the cost to the Value Stream (VS) for conducting an assessment  We did not have a Quality or Communication Plan  We did not understand how this would impact our VS in terms of labor hoursCopyright © 2010 Boeing. All rights reserved.
  12. 12. Future Planning • Leadership  The Vision must be SMART − Specific, Measurable, Achievable, Realistic, Time Phased − Pick the right tool for the job (Accelerated Improvement Workshop (AIW), 3P (Production Preparation Process), Kaizen Event • Factory Organization  Benchmark other companies / areas  Use standard layouts − Paint stalls − Crew Shelters • Employee Empowerment / Teams  Mature the teams that we have  Focus on team metricsCopyright © 2010 Boeing. All rights reserved.
  13. 13. Future Planning continued • Inventory / Supply  Right size delivery method − Tools − Supplies • Manufacturing Processes  Standard Work at the operator level  Root Cause Analysis − Make it a repeatable process everyone can use • Continuous Improvement  Common processes  Standard work  Cell metricsCopyright © 2010 Boeing. All rights reserved.
  14. 14. 2010 Business Plan We are using the results from the assessment to build our business plan • We included  Creating Standard Work  Creating Cell Metrics  Supplies / Delivery methods  Planning for our next Lean Manufacturing AssessmentCopyright © 2010 Boeing. All rights reserved.
  15. 15. Summary Back to basics • Scope Statement • Stakeholders • Work Breakdown Structure • Risks • Communication Plan • Roles and ResponsibilitiesCopyright © 2010 Boeing. All rights reserved.
  16. 16. Lean Manufacturing Lessons LearnedCopyright © 2010 Boeing. All rights reserved.
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