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Moonshine Process at Boeing – Focus on Function, Flow & Equipment. Earl S. Robinson Jr Senior Lean Practitioner Boeing Commercial Airplanes. SLM800137702-01.ppt. Moonshine Process at Boeing. What we will discuss today A high-level look at the role of Lean+ at The Boeing Company

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moonshine process at boeing focus on function flow equipment

Moonshine Processat Boeing – Focus on Function, Flow & Equipment

Earl S. Robinson Jr

Senior Lean Practitioner

Boeing Commercial Airplanes

SLM800137702-01.ppt

moonshine process at boeing
Moonshine Process at Boeing
  • What we will discuss today
    • 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 and the big picture
Lean+ and the Big Picture

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.

quality flow stability

Continue to invest in market driving products, features and services that improve our competitiveness

Quality, Flow, Stability

Growth and Productivity - Six Focus Areas

Working together to provide preferred products and services that enable our customers to be more successful!

Creating Value for All!

moonshine process at boeing1
Moonshine Process at Boeing
  • Moonshine refers to an improvement activity that is formally known as the “Production Preparation Process” (3P)
  • Purpose
    • 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
  • Considered an advanced Lean+ technique
    • Incremental improvement
    • Breakthrough improvement, redesign
what is moonshine and it s relationship to lean
What is Moonshine and it’s Relationship to Lean?

Moonshine Process at Boeing

  • 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.
what is moonshine and it s relationship to lean1
What is Moonshine and it’s Relationship to Lean?

Moonshine Process at Boeing

  • 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.
  • During 3P (Production Preparation Process) workshops, concept simulation is introduced after 7 Ways have been developed and down-selected 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.
moonshine process at boeing2
Moonshine Process at Boeing
  • The steps of 3P
    • 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
slide9

Process Change/Relocation

New Product

Chronic Problem Areas

Major Production Rate Change

Existing plan does not meet performance metrics

Product Design Change

Business Case

New Process

3P Steps

  • Implementation:
    • Flow lines & feeders
    • Poka-Yoke
    • Standard Work
    • Equipment/Tool Fabrication

Training

Final

Process-at-a Glance

Fishbone,

Process Flows

Production Preparation Process

Trials &

Simulations

Process

Evaluation

7 Ways Sketches

moonshine process at boeing3

Kaikaku

Kaikaku

Rate with AIW’s alone

Moonshine Process at Boeing
moonshine process at boeing4
Moonshine Process at Boeing
  • How Do We Accomplish Moonshine at Boeing?
    • 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
moonshine process at boeing5
Moonshine Process at Boeing
  • Benefits
    • Right-sized assets
    • High-quality products
    • Standard, reliable methods
    • Dramatic reductions in cost, inventory and lead time
    • Improved quality
  • Key deliverables
    • A simulation of the improved process
    • An implementation plan
    • An equipment development plan
    • Resource requirements
    • Implementation timeline
    • A right-sized flowing production system
moonshine process at boeing examples
Moonshine Process at BoeingExamples

Bracket Chaku Chaku Line

moonshine process at boeing examples1
Moonshine Process at BoeingExamples

Blanking Press withQuick-Change Blanking Tool

Material FIFO Device

moonshine process at boeing examples2
Moonshine Process at BoeingExamples

Right-sizedPaint Booth and Dryer

AssemblySeal Cure

moonshine process at boeing examples3
Moonshine Process at BoeingExamples

Hydraulic Tube Net Trim

Stowbin NC Router

moonshine process at boeing examples4
Moonshine Process at BoeingExamples

“Tugbots”

Vacuum Form Hood

moonshine process at boeing moonshine war competition
Moonshine Process at BoeingMoonshine War Competition

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.

moonshine process at boeing moonshine war solutions
Moonshine Process at BoeingMoonshine War Solutions

Stow Bin RailAuto-Deburr

Wing HeliumPressure TestDoors

moonshine process at boeing review
Moonshine Process at BoeingReview
  • The steps of 3P
    • 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