Lean+ | One Overarching Continuous Improvement Approach
BOEING is a trademark of Boeing Management Company.
Copyright © 2011 Boeing. All rights reserved.
SLM800137702-01.ppt

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach

– A high-level look at the role of Lean+ at The Boeing Company
– A definition of Moonshine at Boeing
– Examine the steps of the Moonshine process
– Share some examples of Moonshine activities
– We will learn more about some of the steps by trying them
– Have a dialogue about Moonshine and improvement
Lean+
Copyright © 2011 Boeing. All rights reserved.

Lean+
Lean+ and the Big Picture
Lean+ | One Overarching Continuous Improvement Approach
Boeing is pursuing four initiatives to accelerate long-term growth and productivity gains across the enterprise:
 Lean+
 Internal Services Productivity
 Global Sourcing
 Development Process Excellence
Lean+ is the foundational initiative and the key to success with the others. It is the one overarching continuous improvement approach at
Boeing and aligns with Lean, Employee Involvement & Engagement,
Six Sigma, Process Management, Project Management and Theory of Constraints, among others.
Copyright © 2011 Boeing. All rights reserved.

Lean+
Quality, Flow, Stability
Lean+ | One Overarching Continuous Improvement Approach
Working together to provide preferred products and services that enable our customers to be more successful!
Continue to invest in market driving products, features and services that improve our competitiveness
Creating
Value for
All!
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach


– Improve the flow of a production process by developing production engineering redesigns, right sized equipment and processes that focus on the transformational steps
– To “re-engineer” the process

– Incremental improvement
– Breakthrough improvement, redesign
Copyright © 2011 Boeing. All rights reserved.
Lean+

Lean+
Moonshine Process at Boeing
What is Moonshine and it’s Relationship to Lean?
Lean+ | One Overarching Continuous Improvement Approach
 The term “Moonshine” used at Boeing is something we learned from our
Lean teachers. They explained it as work that was done at night, away from normal process work, where those who do the work can put their improvement ideas into concepts and prototypes, presenting them to management when they had a completed idea.
 In the US the term is derived from the days when individuals illegally made their own liquor during Prohibition. These individuals would
"borrow" ideas and test each other's liquor to see what tasted the best and then adopt the best methods
 Both definitions are similar. They use the ideas of people familiar with the product or process, use inexpensive material or anything they could find to make their own equipment. The production activity was done under the cover of night (or away from other processes). The best ideas from those making the product were/are tried (simulated) and the best methods are adopted.
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
What is Moonshine and it’s Relationship to Lean?
Lean+ | One Overarching Continuous Improvement Approach
 Simulation is the essence of Moonshine. Moonshine as we know it means to "trystorm (simulate)" and "spend no money" to do what it takes to get the job done right. It is not to condone illegal or unsafe activity.
Lean+
 During 3P (Production Preparation Process) workshops, concept simulation is introduced after 7 Ways have been developed and downselected to two or three ideas. Moonshine develops these ideas into physical models that are then used for production simulations. During the simulations, the models are continually evaluated and refined until a superior design proposal emerges
 After the product/process concept proposal from the 3P is complete the proposal must be tested to meet safety and production requirements and be incorporated into standard work or operations.
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach

– Define the function, theme and scope
– Use keywords to define the function
– Find examples of the keywords in Nature
– Examine what’s happened, sketch and post examples
– Sketch the background and conditions
– Combine ideas and create sketches of them; think of at least seven ways
– Select the best proposals
– Construct prototypes; continue “moonshining”, or innovating
– Conduct simulations
– Gather and evaluate data; keep moonshining
– Review the process with the customer to select the top design
Copyright © 2011 Boeing. All rights reserved.
Lean+

New Process
• Flow lines & feeders
• Poka-Yoke
Lean+ | One Overarching Continuous Improvement Approach
• Standard Work
• Equipment/Tool Fabrication
Business Case
Process Change/Relocation
New Product
Chronic Problem Areas
Major Production
Rate Change
Existing plan does not meet performance metrics
Product Design Change
Lean+
Training
Final
Process-at-a Glance
Trials &
Simulations
3P Process Evaluation Checklist
17
18
19
20
21
22
11
12
13
14
15
16
23
24
25
8
9
10
5
6
7
1
2
3
4
Process: ________________________________
Vote each proposal one at a time based upon its own merit. Do not evaluate proposals against each other.
Everyone votes 1 - 5. Do not use zero. Do not average. The most repeated score should be recorded.
Proposals
Evaluation Criteria
Ability to Meet Takt Time
1 2 3 4 5 6
Creates One-Piece-Flow
Minimum Standard Work In Process (SWIP)
Minimum Operator Involvement (Hands-free Operations)
Poke-Yoke Built In
100% Gauging or Check Fixtures
Process Capable of Quality Products
Minimal Capital Required
Low Tooling Costs
Low Changeover/Set-Up Times
Known or Existing Process
Known Technology to Boeing
Low Level of Tool Maintenance
Minimal Development Time is required
Maintenance free Equipment or Easy/Fast Autonomous Maintenance
Standard Equipment is Used
Utilizes Right-Sized, Process Capable Equipment
High Level of Value-Adding Operations
Ergonomics and Safety Issues Addressed
Level of Jidoka Achieved (Autonomation)
Fits the CHAKU-CHAKU concept
Creates a Competitive or Technological Advantage
Space Utilization. Townhouse design
Mobility: On wheels, no roots or vines
Simple as Possible
Total:
Rating: 5 = Excellent; 4 = Above Average; 3 = Average; 2 = Below Average; 1 = Poor;
7
Process
Evaluation
Copyright © 2011 Boeing. All rights reserved.
Fishbone,
Process Flows
7 Ways Sketches

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
3P Simulation Exercise
Lean+ | One Overarching Continuous Improvement Approach
Evaluation Criteria
10
11
12
1 Flight Accuracy
2 Flight Distance
3 Flight Duration
4 Ability to Meet Takt Time
5 Enables One-Piece Flow
6 Quality Rqmnts Known (Go/No Go)
7 Process Capable of Quality Products
8 High Level of Value-Added Operations
9 Ergonomics/Safety Issues Addressed
Total:
Proposals
1 2 3 4 5 6 7
0 0 0 0 0 0 0
Copyright © 2011 Boeing. All rights reserved.
Lean+

Moonshine Process at Boeing
3P Simulation Exercise
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
3P Simulation Exercise
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Kaikaku
Kaikaku
Rate with AIW’s alone
Copyright © 2011 Boeing. All rights reserved.

Lean+
Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach

– Sensei’s
– Certified 3P Practitioners
– Management Sponsorship of Projects
– Creation of Moonshine Shops
 Link projects to business goals, safety for employees, competitive advantage
 Creative Thinkers, cross functional team members
 Place to conduct Moonshine Projects (equipment, materials, time)
– Moonshine Shops
– Creation Shop
– Innovation centers
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach

– Right-sized assets
– High-quality products
– Standard, reliable methods
– Dramatic reductions in cost, inventory and lead time
– Improved quality

– A simulation of the improved process
– An implementation plan
– An equipment development plan
– Resource requirements
– Implementation timeline
– A right-sized flowing production system
Copyright © 2011 Boeing. All rights reserved.
Lean+

Moonshine Process at Boeing
Examples
Lean+ | One Overarching Continuous Improvement Approach
Bracket Chaku Chaku Line
Lean+
Copyright © 2011 Boeing. All rights reserved.

Lean+
Moonshine Process at Boeing
Examples
Lean+ | One Overarching Continuous Improvement Approach
Blanking Press with
Quick-Change Blanking Tool
Material FIFO Device
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Examples
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Copyright © 2011 Boeing. All rights reserved.
Right-sized
Paint Booth and Dryer
Assembly
Seal Cure

Moonshine Process at Boeing
Examples
Lean+ | One Overarching Continuous Improvement Approach
Hydraulic Tube Net Trim
Lean+
Stowbin NC Router
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Examples
Lean+ | One Overarching Continuous Improvement Approach
“Tugbots”
Lean+
Vacuum Form Hood
Copyright © 2011 Boeing. All rights reserved.

Right Sized Equipment
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Moonshine War Competition
Lean+ | One Overarching Continuous Improvement Approach
Lean+
An annual event where teams compete using the 3P approach to develop solutions to actual workplace efficiency and safety issues. Three teams compete on one of up to seven projects. Prizes are awarded for each project, and a Grand Prize is awarded to the team judged to have developed the best overall solution using the moonshine process.
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Moonshine War Solutions
Lean+ | One Overarching Continuous Improvement Approach
Stow Bin Rail
Auto-Deburr
Lean+
Copyright © 2011 Boeing. All rights reserved.
Wing Helium
Pressure Test
Doors

Moonshine Process at Boeing
Review
Lean+ | One Overarching Continuous Improvement Approach

– Define the function, theme and scope
– Use keywords to define the function
– Find examples of the keywords in Nature
– Examine what’s happened, sketch and post examples
– Sketch the background and conditions
– Combine ideas and create sketches of them; think of at least seven ways
– Select the best proposals
– Construct prototypes; continue “moonshining”, or innovating
– Conduct simulations
– Gather and evaluate data; keep moonshining
– Review the process with the customer to select the top design
Lean+
Copyright © 2011 Boeing. All rights reserved.

Moonshine Process at Boeing
Lean+ | One Overarching Continuous Improvement Approach
Lean+
Copyright © 2011 Boeing. All rights reserved.

© 2011 Boeing. All rights reserved.
BOEING is a trademark of Boeing Management Company.