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NAVSEA LEAN Presented By Maggie Maguire NAVSEA Comptroller 13 June 2005 PowerPoint Presentation
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NAVSEA LEAN Presented By Maggie Maguire NAVSEA Comptroller 13 June 2005. It’s a Journey – Not a Destination. Goals and Objectives Improve productivity and return on investment Support any efforts that are already underway Change the culture Incorporate Lean into the line organizations.

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Presentation Transcript
slide1

NAVSEA LEAN

Presented By

Maggie Maguire

NAVSEA Comptroller

13 June 2005

It’s a Journey – Not a Destination

navsea lean
Goals and Objectives

Improve productivity and return on investment

Support any efforts that are already underway

Change the culture

Incorporate Lean into the line organizations

NAVSEA LEAN
navsea lean is
Integrated and Aligned with

ASN (RD&A) Source Document, “Blueprint for the Future”

DASN (Logistics) Lean Efforts

Applicable to all lines of business, product lines, and processes across HQ/PEO/Field Activity enterprise for

direct, direct support, and overhead work

Consistent with NAVSEA’s overarching business strategy/approach for continuous improvement

Incorporates Lean, Six Sigma, Theory of Constraints Critical Chain Project Management, BPR…..

NAVSEA Lean is…
lean concepts and principles
Key terms

Value/ Value stream

Flow

Muda

Type One –unavoidable in current system

Type Two - avoidable

Customer focus

Pull

Perfection

LEAN CONCEPTS AND PRINCIPLES
slide5

Task Force Lean (TFL)

Organization

COMMANDER

NAVAL SEA SYSTEMS COMMAND

VADM P. BALISLE

SEA 00

VICE CDR/DEP CDR FLEET

MAINT & MOD

EXEC DIR.

SEA 00B

P. BROWN (SES)

SEA 09

RADM A. LENGERICH

Task Force Lean

Flag/SES level

Task Force Support Functions

Lean Efforts

Contracts; legal & financial support as needed

CORPORATE

OPERATIONS

SEA 10

Contract

Support

Warfare Centers

Naval Shipyards

HQ LoB

& PEO

Deploy via Command Lines of Business (LoB)

slide6

Process Improvements FY 2002 - FY 2004

95% Decrease in Overtime Hours

28% Increase in Throughput

92% Increase in Productivity per Labor Hour

60% Improvement in Cycle Time

Average Ball Valve Cycle Time per Quarter

FY 2002

FY 2003

FY 2004

Quarter 1 2 3 4 1 2 3 4 1 2

Cycle Time (days) 208 176 148 140 100 82 61 53 54 45

Goal = 20 Days

PNSY - Ball Valve Repair

“Implementation of Lean Manufacturing Techniques in the Ball Valve Shop is the first and most mature example of a process that is the best in class at PNS and throughout NAVSEA.” - Inspector General Report, March 2004

improving crane availability
Improving Crane Availability

Portal Cranes

Reduced Crane Maintenancefrom 98 to 37 Days

Reduced Overtime Costsfrom $180K to $0

Portal Crane Annual Maintenance Savings $960K/Year

  • Bridge Cranes
  • Category II Bridge Crane Savings $400K/YR
  • 88% Reduction in Maintenance Cycle Time from 30 to 7 days
  • Eliminated Work Backlog
38b ordnance shop first pass
Before

Lead Time: 60 Days

Manpower: 18 Sailors

Inventory: Excessive

Excessive Transportation

Premiums paid to local contractors

Unpredictable quality

After

Lead Time: 3-5 Days

Manpower: 15 Sailors

Inventory: 50% reduction

Transp. waste eliminated

Premiums reduced by $30K per repair not sent to UD

Anecdotal quality increase

Lean in SWRMC

38B Ordnance ShopFirst Pass

Added capability to repair VLS Hatches due to improved gun repair process.

navsea lean business and operations
Currently Approved Projects

Funding Documents

University Affiliated Research Centers

Procurement Requests

NAVSEA LEAN BUSINESS AND OPERATIONS
the lean toolbox not all inclusive
Change Management

Balanced Scorecard Metrics

Value Stream Analysis / Value Stream Maps

Rapid Improvement Workshop

Brainstorming

Win/Win

Prioritization

5 Why's

Theory of Constraints

Nominal Group Technique (NGT)

Team Building & Facilitation

Project Planning

Process Analysis

Causal Loop Diagramming

Process Observation / GEMBA

Six Sigma

Basic Statistics

Data Analysis Tools

Root Cause Analysis

Hypothesis Testing

5 S / Visual Controls

Poke-Yoke / Error Proofing

Pull Systems

Supply Chain Management

The Lean Toolbox(NOT all inclusive)