A1

1
Improving Plant Operating Efficiency through Lean
Production Methods

• Lean Advocate Training

2
Orientation

• Jordan Dentz

3
Orientation

• Project goal
• Introductions
• What is lean?
• Project plan
• Roles and responsibilities
• Training program schedule

4
Project Goal

• Transform the way homes are manufactured,
  substantially reducing manufacturing costs,
  production time, product defects, and labor hours
  per home while improving quality.

5
Method

• Plan and implement cost-justified changes in
  manufacturing process by implementing concepts of
  lean production
• Establish within the plant a culture of
  continuous improvement and develop a system to
  institutionalize these changes

6
Self Introductions

• Cavalier Homes
• Chelsea Modular
• Clayton Homes
• Four Seasons Housing
• Hi-Tech Housing

• Palm Harbor Homes, Albemarle
• Palm Harbor Homes, Plant City
• R-Anell Housing
• Southern Energy Homes

7
MHRA Team

• MHRA project coordination
• Jordan Dentz
• Senco training and plant facilitation
• Dewey Warden
• University of Central Florida - training and
  plant facilitation
• Dr. Michael Mullens

8
Lean What is it?Dr. Mike Mullens, UCF

• A general way of thinking and specific practices
  that focus on using less of everything.
• An approach to manufacturing that transforms the
  plants culture to one in which all forms of
  waste are systematically and continuously rooted
  out at all levels.

9
Lean Guiding Principles
10
Lean Management Perspective

• Is a culture -- not a management technique.
• Focuses on processes -- not just results.
• Applies to both production and office functions.

11
Lean Benefits

• From establishing and mastering a lean production
  system

Source 1000Ventures.com
12
Characteristics of a Lean Factory

• Orderly, clean work place
• Standardized best methods
• Plant layout facilitates continuous flow
• Just-in-time processing driven by customer demand
  or pull
• Single piece or small batch continuous workflow
• Quick changeovers of machines/processes
• Minimal inventories

13
Characteristics of a Lean Factory

• Short order-to-ship cycles times
• Total quality control
• Defect prevention built into processes
• Preventative maintenance
• Team-based continuous improvement
• Partnership-oriented relations with suppliers and
  distributors

14
Milestones

• Select plants
• Train lean advocates
• Map plant value streams
• Develop lean implementation strategy
• Conduct RPI events
• Re-convene to evaluate progress

15
Select Plants

• Cavalier Homes
• Chelsea Modular
• Clayton Homes
• Four Seasons Housing
• Hi-Tech Housing
• Palm Harbor Homes, Albemarle
• Palm Harbor Homes, Plant City
• R-Anell Housing
• Southern Energy Homes

16
Train Lean Advocates

• Train lean advocates in the concepts and
  techniques of lean production
• Charge lean advocates with tasks to complete back
  at their plant

17
Map the Value Stream

• Collect data to describe current plant
  performance
• Develop current-state value stream map
• Identify specific areas for improvement
• Conduct detailed observations and create process
  flow maps of those areas
• Develop future-state value stream map

18
Develop Strategy

• Select areas for improvement
• Develop a strategy for implementing lean
  improvements as depicted on the future-state
  value stream map
• Strategy will be based on conducting at least
  three RPI events

19
Conduct RPI Events

• Train plant staff to participate in RPI events
• Conduct at least three RPI events
• Document and evaluate the RPI events
• Report results to plant management
• Plant lean advocates will be encouraged to
  conduct additional RPI events in between
  advisory team member visits

20
Re-convene to Evaluate Progress

• One-day de-briefing where all participants will
  share experiences

21
Schedule

• April Training
• May Value stream mapping
• June - September RPI events
• November Final team meeting

22
Key Players and Their Roles

• Plant management support
• Lean advocates facilitate, lead
• Plant staff participate
• MHRA team (MHRA, Senco, UCF) guide

23
Plant Management

• Assign senior staff members as the lean advocates
• Make available other plant staff as necessary to
  assist the lean advocates
• Support of senior management for lean activities

24
Lean Advocate

• Approximately 200 hours
• Pivotal members of the project team
• Develop value stream maps
• Train plant staff
• Lead RPI events
• Document RPI events
• Participate in final team meeting

25
Plant Staff

• Support the data collection effort
• Undergo pre-RPI training lead by the lean
  advocates
• Participate in RPI events
• Participate in the continuous improvement process

26
MHRA Team

• Dentz overall project coordination
• Warden and Mullens serve as primary team contact
  for 4 or 5 plants
• Responsibilities
• Guidance on value stream mapping
• Feedback and input on strategy
• Facilitate RPI events
• Four visits to each plant
• Be a sounding board for any lean issues for the
  duration of the project

27
Plant Assignments

• Cavalier Homes
• Chelsea Modular
• Clayton Homes
• Palm Harbor Homes, Plant City
• Southern Energy Homes
• Team contact Michael Mullens

• Four Seasons Housing
• Hi-Tech Housing
• Palm Harbor Homes, Albermarle
• R-Anell Housing
• Team contact Dewey Warden

28
Agenda - Monday

• Orientation 800 to 900
• Senco plant tours 900 to 1200
• Visit to daily accountability meeting room 1200
  to 1230
• Lunch and panel discussion 1230 to 130
• Sencos Lean Transformation and Management
  Commitment 130 to 230
• Lean Basics 230 to 400
• Demonstrations 400 to 530

29
Agenda - Tuesday

• Value stream mapping current state
• Case study
• Value stream mapping exercise
• Review of exercise

30
Agenda - Wednesday

• Value stream mapping future state
• Case study drawing the future state
• Value stream mapping exercise future state
• Review of exercise

31
Agenda - Thursday

• RPI event overview
• The 5 Ss
• Plant focus areas

32
Agenda - Friday

• Review of lean topics
• Next steps discussion of assignments
• Tools
• Wrap-up

33
Daily Schedule

• Meet in hotel lobby 700 for ride to Senco
• Breakfast 730 in Senco training room
• Lunch in Lean Management Training Room
• Ride back to hotel
• Dinner meet in hotel lobby 630pm

34
In Conclusion

• Ask questions
• Share ideas
• Debate concepts
• Discuss past experiences
• After each concept is introduced how can this
  apply to a housing plant?