Factory Building Symposium on Lean Production January 29, 2007 Austin, Texas
Finding the Right Fit Clayton Homes Andersonville, TN Brent Crabtree, Lean Advocate
Clayton Appalachia Started: Location: Home types: Price point : Design: Production: Market area: 1994 Andersonville, TN HUD Code Moderate No customization 10 to 18 floors/day 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 Now Then Damage Congestion Productivity WIP Workstations Piles of WIP overexcessivequeue WIP between in WIP flowed into traffic Continuous and workand with no aisles Clear traffic aisles Batch cell conveyance resulted One-third the WIP damaged doors
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 doors 2 houses of doors 33% less 40 hours 20. 4 hours 50% less 65 doors/day 200+ doors/day 300% more Flow time Productivity with 2 team members
Final Finish Then Now Productivity Materials farexcess transport and removed excessive motion Eliminated from point of need, leading to unneeded items and conveyance
Results Per house Before After Change Walking 1. 3 mi 0. 6 mi 54% less Trips 22 13 41% less Space 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
Factory Building Symposium on Lean Production Manufactured Housing Research Alliance Jordan Dentz (212) 496 -0900 x 13 jdentz@research-alliance. org www. mhrahome. org
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