Lean Enterprise Approach for Programs
Program A
Business Goals/Objectives:
Year 20xx
Cost = $w
Cycle time = x mo.
Inventory turns = y
EP = z
Value Stream Mapping
and Analysis
Transfer
Customer I/F to
Gate
COSC
19
BM I&T
Gate
Gate
18
I
Gate
6U
Validate Config,
VCRI, Eng &
Gate
Test Plans
2
S/C Mate
S/C I&T
Gate
10
Gate
12
PULL
Antenna I&T
Gate
12A
Validate & Install
MCC S/W &
Gate
Database
15
Gate
6A
RT SS Build, On
Station ROPs,
Gate
SCF FAT
16
Gnd System
Delivery &
Validation
EP Calculator
Gate
17
Current State
Value Stream Map
Transfer
Customer I/F to
Gate
COSC
Weekly Gate
Schedule
Updates (ESS)
Bus Layout
/ Design
Proposal &
Bus Struct
Build
Gate
Negotiation
Gate
I
PULL
7
1
Bus Units Fab,
Assy, Test
Unit Req't
Unit Design
Definition
Bus Layout
/ Design
Proposal &
Negotiation
Bus Struct
Build
Gate
BM I&T
Gate
3
Gate
7
9
Develop B/L
Schedule, SOW,
Config, Specs
Validate Config,
VCRI, Eng &
Gate
Test Plans
2
Bus Units Fab,
Assy, Test
Gate
4
Gate
8U
3
S/C I&T
Gate
8
Gate
Gate
12
13
10
PULL
PUSH
Gate
6
Launch
Contractor
1A
2
P/L Layout /
Design
PU LL
I
Solar Array
I&T
P/L Products
Fab, Assy, Test Gate
8U
3
Gate
4
PULL
Design
Gate
6A
S/C I&T
Gate
12
Ant Layout /
Design
Launch
Contractor
Gate
13
PUSH
Gate
14
Launch Site
Ops
Antenna I&T
Gate
Gate
5
Satellite Ops
S/C Mate
Gate
10
PULL
Gate
12A
Gnd Segment,
Sat / Mission Ops
Gate
Definition
2A
PLM I&T
Gate
8
I
System Design,
Eng & I&T Plans Gate
6
LL
Gate
11
Gate
6U
PU
Gate
5
Gate
18
I
Unit Design
Gate
2U
Validate Config,
VCRI, Eng &
Test Plans
Gate
Gate
14
Launch Site
Ops
Antenna I&T
Unit Req't
Definition
Gate
LL
I
S/C Mate
PU
System Design,
Eng & I&T Plans
Ant Layout /
Design
PLM I&T
PULL
P/L Products
Fab, Assy, Test Gate
Mission Ops
Gate
7U
P/L Layout /
Design
I
PULL
Gate
1
Gate
6U
Gate
2U
1A
Gate
18
I
7U
Gate
Mission Ops
Gate
Transfer
Customer I/F to
Gate
COSC
19
Weekly Gate
Schedule
Updates (ESS)
9
Gate
Develop B/L
Schedule, SOW,
Config, Specs
19
BM I&T
Gate
3
PUSH
Satellite Ops
Design
PULL
I
Solar Array
I&T
Gnd Segment,
Sat / Mission Ops
Gate
Definition
2A
Lean Assessment
Gate
14
PULL
PULL
Gate
11
Launch Site
Ops
PUSH
Gate
5
Launch
Contractor
Gate
13
PUSH
LL
Ant Layout /
Design
PLM I&T
Gate
8
I
Gate
6
PU
System Design,
Eng & I&T Plans
PULL
P/L Products
Fab, Assy, Test Gate
8U
3
Gate
4
PU LL
P/L Layout /
Design
PU LL
Gate
7U
Unit Design
Gate
2U
PULL
Bus Units Fab,
Assy, Test
Unit Req't
Definition
Mission Ops
PULL
PULL
Gate
1
Develop B/L
Schedule, SOW,
Config, Specs
Gate
1A
9
I
PULL
7
PULL
Gate
3
PULL
Bus Struct
Build
Gate
PUSH
Weekly Gate
Schedule
Updates (ESS)
Bus Layout
/ Design
Proposal &
Negotiation
11
Validate & Install
MCC S/W &
Gate
Database
15
I
PULL
Solar Array
I&T
Gate
12A
RT SS Build, On
Station ROPs,
Gate
SCF FAT
16
Gnd System
Delivery &
Validation
Gate
17
Gnd Segment,
Sat / Mission Ops
Gate
Definition
2A
Satellite Ops
Design
Gate
6A
Validate & Install
MCC S/W &
Gate
Database
15
RT SS Build, On
Station ROPs,
Gate
SCF FAT
16
Future State (1-2 yrs)
Value Stream Map
Gnd System
Delivery &
Validation
Gate
17
Results!
Future Vision (3-5
Cost = $wyrs)
Cycle time = x mo.
Value Stream Map
Inventory turns = y
Pareto Analysis
“Dial Chart”
EP = z
PAS 1R Critical Path Cummulative Cost
Planned No.
Planned
Reference
80%
Reqts to Unit Analysis: Gates -1,1,1A,2,2U,4,6U
Bus Dsn & Units: Gates 3,7, 7U&8U (bus)
P/L Dsn & Units: Gates 4,8,10, 7U&8U (p/l)
Antenna: Gates 5, 11
17.3
10.8
24.4
12.3
30
20.4
18.2
34.1
10.9
47.1
0.7
I&T: Gates 8,9,10,12,12A,13
Sat Ops: Gates 2A,6A,14-18
18.8
9.7
52.8
100
29.1
0
Programs
Spaceway 702
Wideband Gapfiller 702
Anik F2 702
60%
40%
ste
sid ms
er
ati
on
rit
s
y
1
5
Area)
Requirements Forecast. Lay-
Operations
out factory for flow
Workshop
Date(s)
of
Pre-Workshop
Workshop
Days
Workshop
Phone
Lean Office
Responsible
Number
Facilitator(s)
4.0
Workshop
Type
3P
Training
Required
Lean Overview
Create Gated Process
io
on
Pr
C
c
-
2
6
3
4
Workshop Title (Focus
Organization
Factory
Owners that focus on
2
Gate Processes
100%
Workshop for
10 Year Facility
1
Sy
ati
m
on
e
m
or
/N
ra
C
e
og
or
C
Pr
C
120%
Number
os
t
Le
ve
ra
ge
C
Sc ycle
he T
d im
L e e/
ve
Q
ra
ua
ge
Le lity
ve
ra
ge
C
um
ula
tiv
Va e
lu
e
Lean Implementation BSS
Leverage Area Evaluation
Factory
improvements across silos,
Operations
functions, and programs
Factory
Create Gated Process Dollar
3
Operations
Metrics with visuals
Implement a
4
MASS Project
the Work Cells
5
MASS Project
project based Work Cells.
Change infrastructure
6
MASS Project
create standard work
I&T AIW Workshop for Bus
7
MASS Project
standard work
I&T AIW Workshop for
3.0
AIW
Lean Overview
3.0
AIW
Lean Overview
3.0 Ray Coyle
AIW
Lean Overview
4.0 Ray Coyle
AIW
Lean Overview
communications process for
Create Process based vs
I&T AIW Workshop for Bus
Module Integration Phase to
4.0 Harold Rice
AIW
4.0 Bob Berry
AIW
Lean Overview
4.0 Open
AIW
Lean Overview
Lean Overview
4.0 Marian Chao
AIW
Lean Overview
Module Test Phase to create
N/A
N/A
N/A
1
4
3
Payload Module Integration
8
N/A
N/A
Ebird 376HP
JCSAT 8 601HP
Galaxy 8iR 601HP
Asiasat 4 601HP
Galaxy 13 601HP
N/A
N/A
N/A
N/A
N/A
2
Phase to create standard
I&T AIW Workshop for Bus
Module Test Phase to create
9
New Skies 702
GOES 601
TDRS 601
MASS Project
MASS Project
standard work
I&T AIW Workshop for
Integration Phase to create
10
MASS Project
11
MASS Project
12
MASS Project
13
MASS Project
14
MASS Project
standard work
4.0 Mike Sheets
AIW
Lean Overview
I&T AIW Workshop for Initial
System Integration Test
20%
Phase to create standard
work
4.0 Bob
AIW
Lean Overview
4.0 ???
AIW
Lean Overview
I&T AIW Workshop for
Spacecraft Thermal Vacuum
Phase to create standard
work
I&T AIW Workshop for
Spacecraft Thermal Vacuum
0%
Bus Phase to create
standard work
4.0 Cathi Graham
AIW
Lean Overview
4.0 Shawn Struc
AIW
Lean Overview
I&T AIW Workshop for
Spacecraft Thermal Vacuum
1 to 4
4 to 8
8 to 12
12 to 13
1 to 17
13 to 18
Payload Phase to create
standard work
I&T AIW Workshop for
Spacecraft Thermal Vacuum
Thermal Phase to create
15
MASS Project
16
MASS Project
standard work
4.0 Richard Warren
AIW
Lean Overview
4.0 Kirt Bogan
AIW
Lean Overview
I&T AIW Workshop for
Space Simulation Laboratory
Phase to create standard
Cumulative Cost
Curve
Prioritized opportunities
for improvement
work
Microsoft Project
Lean Implementation Plan
• Training
• Workshops
• Events
Jan M. Martinson/Lean Enterprise Approach for Programs 041503