Lean Aircraft Initiative
Plenary Workshop
Factory Operations Focus Team
March 5, 1997
Presented by:
Tom Shields
MIT
LEAN AIRCRAFT
INITIATIVE
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Outline
Phase I research
Phase II research direction
Research activities
Next steps
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FO030597-2 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
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Phase I Research Report
Inventory survey and case studies
– Baseline for the industry
– Front end loading of inventory
– Two recommendations for improvement
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Benchmarking nonsponsor companies
Comparative case studies
– Flow optimization
– Variability reduction
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Focused case studies
Lean implementation considerations
Member flow benchmarking
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FO030597-3 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
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Phase II Research
Considerations
Identifiable and practical deliverables
Meaningful to senior management
LEM used as a guide for research
Extendible to the enterprise level
Balanced breadth and depth of research
Linked to Implementation IPT
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LEAN AIRCRAFT
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Strategic Approach
Build on the LEM
Conduct on-site field research
Drill down to prioritized metrics/enabling
practices (using “Order to point of use
delivery cycle time” as initial metric)
Use appropriate models to analyze
interactions of key factors
Use models as decision tools
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FO030597-5 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
Example Deliverables
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Production system benchmarking
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Models for analysis and decision
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FO030597-6 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
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Phase II Factory Operations
Research
Better understanding of assembly stage
Identification of appropriate metrics
Identification of causes for deviation in
assembly cycle time
Recommendations for leaner systems
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FO030597-7 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
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Research Activities Starting
September 1996
Visits to member assembly facility
– Weekly visits (234 person hrs)
– 2 week stay in January (28 person days)
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Development of process maps
Detailed tracking of specific serial
numbers for product types during build
Analysis of archival data of recent builds
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FO030597-8 ©1997 Massachusetts Institute of Technology
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On-site Visits
Collection of module build status
documentation at assembly areas
Identification of delay causes, if any, with
Cell Leaders, Lead Persons, Operators,
Schedulers, etc.
Identification of waste
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FO030597-9 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
Process Maps
Sub Assembly 1
Sub Assembly 6
Sub Assembly 2
Sub Assembly 7
Sub Assembly 3
Sub Assembly 8
Sub Assembly 4
Sub Assembly 9
Sub Assembly 5
Sub Assembly 10
Storage
Transportation
Test
Assembly
Operation
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FO030597-10 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
Subassembly Process Maps
Flow
operation 1
operation 2
operation 9
operation 16
operation 10
operation 3
operation 4
operation 11
operation 18
operation 12
operation 5
Storage
operation 13
operation 6
operation 20
operation 14
Flow
operation 15
Transportation
Value-Adding
Operation
Inspection
Non-Value-Adding
Operation
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FO030597-11 ©1997 Massachusetts Institute of Technology
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Reasons for Increment in
Cycle Time
Part shortages (outside source)
Part not found but ‘available’
People not available
Built awaiting inspection
Quality problem
– part quality
– work quality
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Tooling availability
Station availability
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FO030597-12 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
INITIATIVE
Lean Changes Vs. Reality
Several lean changes are readily understood, but
barriers exist ...
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External Conditions
Contract conditions
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with customer
with supplier
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Suppliers are limited
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business reasons
there aren’t that many
capacity
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Internal Conditions
Performance measurement
system
Need to work with upper
management to meet
requirements for lean
transition
Workforce issues
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much overtime
flexibility
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FO030597-13 ©1997 Massachusetts Institute of Technology
LEAN AIRCRAFT
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Next Steps
Continue research at field sites
– Multiple sites in same sector
– Multiple sectors
– Engine sector in 1997
– Airframe and Electronic sector in 1998
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Propose experiments and monitor results
Develop models or decision tools
Product transition to production study
starting in 1998
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FO030597-14 ©1997 Massachusetts Institute of Technology