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Factory Building Symposium on Lean Production. January 29, 2007 Austin, Texas . Palm Harbor Homes Albemarle, NC Allen Tucker, Production Manager. Clutter to Cash. Palm Harbor Albemarle. Goal: Free Space in the Plant. Obsolete and damaged material Unneeded equipment

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factory building symposium on lean production

Factory Building Symposium on Lean Production

January 29, 2007Austin, Texas

goal free space in the plant
Goal: Free Space in the Plant
  • Obsolete and damaged material
  • Unneeded equipment
  • Poor organization of space
  • No system to flush items not needed for production from production space
palm harbor s strategy
Palm Harbor’s Strategy
  • Departments submit lists
  • Items moved to red tag area
  • Count and value estimates prepared
  • Team meets to examine the items and decide their fate
  • Decision is carried out as soon as possible
  • Process repeats weekly
  • Allen Tucker, production manager
  • Tommy Rogers, special projects manager
  • Darrell Story, supervisor of cabinets, doors, trim depts.
  • Mark Burke, purchasing manager
  • Deedy Hatley, assistant purchasing manager
  • Doug Eudy, quality assurance manager
  • Dalton McCollum, inventory control supervisor
  • Form RPI team
  • Designate red tag area
  • Develop red tag process
  • Implement red tag system

Lean principle: written standard operating procedures

results
Results
  • Welding, plumbing, ceramic, trim and final areas are less cluttered and more organized
  • Recovered $7,603 in obsolete molding
  • Recovered $1,689 from obsolete ceramic tile
  • Recovered $1,760 from obsolete light fixtures
  • Total saved to date $21,282
highlights
Highlights
  • Using lean to clear space and generate cash
  • Team allows fast action
  • Keeps purchasing and sales on their toes
  • Empowers people
  • Increases involvement in lean
  • Improves teamwork
roof plastic
Roof Plastic

Then

  • Small, unstable and awkward work platform
  • No material staging
  • Unsafe rolling procedure
slide10

Roof Plastic

Now

Now

  • Large stable platform full width of module
  • Material staging on platform
  • Access for supply from fork truck
  • Plastic rolls mounted on spool

Lean principles: “Five Ss”, ergonomics

results11
Results
  • Cost $10,000 in materials and $3,000 in labor
  • Safer roof access and application
  • Cycle time reduced
  • Fewer workers required
  • Additional platforms under consideration
going forward
Going Forward
  • “Five S” program
  • Red tag system
  • Racks, jigs and fixtures
factory building symposium on lean production14

Factory Building Symposium on Lean Production

Manufactured Housing Research Alliance

Jordan Dentz

(212) 496-0900 x13

jdentz@research-alliance.org

www.mhrahome.org