JobshopLean Out-brief

1. JobshopLean Out-brief Brian Mayer Virginia Tech Southeast Regional Maintenance Center

2. Resources • SERMC • Jim Holland • Lean Champion • Tom Zbell • Virginia Philpott Manufacturing Extension Partnership • Dr. Shahrukh Irani • Associate Professor, Ohio State University • Developer, PFAST • Director, JobshopLean Initiative

3. Project Background JobshopLean Approach Focused Factories Virtual Cells Pre-project Analysis and Research Done SERMC Current State Data Collection Production Flow Analysis Preliminary Opportunities Project Focus for SERMC Focused Factory for Dive Shop Simulation Benefits 2nd Deck Office Lean MSMO Table of Contents

4. SERMC - Guild-type facility Each shop is based around a skill (or skill set) and not a specific repair job Each job needs multiple steps/tasks done in multiple shops Multiple jobs flowing across different shops creates waste and delays Project Background

5. “Toyota” Lean Low-variety High-volume “Jobshop” Lean High-variety Low-volume Examples: Collision repair shop Tool and die shop RMC Pipe Shop Machine Shop Sheetmetal Shop Pump Shop Valve Shop JobshopLean for SERMC Focused Factories Co-locate a group of shops in one area (Manufacturing Cell) Create a single shop with multiple skill sets to handle a group of jobs JSL software helps to choose the best groups of shops to implement with most effective results Virtual Cells Grouping w/o co-location but with JIT communication Dedicated set-ups and tooling on specific machines JobshopLean for SERMC

6. Virtual Cells Reduce communication delays Reduce queuing delays Do not reduce transportation waste Do not reduce operator motion waste Some facility relayout $$$ Flexible to mix and volume changes No cost of cross-training Focused Factories Reduce communication delays Reduce queuing delays Reduce transportation waste Reduce operator motion waste Increase facility re-layout $$$ Inflexible to mix and volume changes Increase cost of cross-training Focused Factories vs. Virtual Cells

7. Pre-Project Analysis and Research Done

8. LWC has 4 different material flows with AWC’s Equipment People (skills & support) Materials & Machines Information, Knowledge and Decisions LWC has 4 specific types of communication flows with AWC’s Phone Email Person 2 Person Meeting Impact on SERMC performance Communication delays Queuing delays Transportation delays Operator motion delays Scheduling delays Long throughput time SERMC Current State

9. Data Collection • Whole Facility • CASREP’s closed from 10/05-5/06 • Analysis of each shop both HM&E and Combat Systems + Dive (excl. Planning/Scheduling) • Job specific details • AWC • Frequency of interaction • Type of interaction • Role of NEMAIS

10. Production Flow Analysis

11. 952D 956G 936H 953A 935C 952H 983A 937E 936I 952L 000A 937I 934E 955C 935M 936A 935J 935B 934I 937G 935K 936E 935D 936M 952I 935I 990A 935L 937D 936B 934B 936N 934D 935H 937F 935F 934A 935N 936F 934F 935G 935E PFAST OutputsUsed • Analysis • Quantity, Revenue, and Routing of Jobs • Flow Diagram for inter-shop traffic • Example • Clusters formed by JSL software suggested a Dive Shop focused factory

12. Virtual Clusters at SERMC • Cluster Compositions (see handout) • What it will take • Redistribute machines between shops and cross-train personnel to eliminate inter-shop flows • Strategically choose subcontractors based on lead time and not part cost • Increase shop visibility using visual displays and/or NEMAIS • Absorb smaller AWC’s into larger LWC’s based on shop clusters • Waterstriders • Restructuring of production floor • IT supported wireless communications between shops, material handlers, and NEMAIS • Finite Capacity Scheduling module to be added to NEMAIS • Dynamic visual displays in shops and branch offices

13. Planning & Supply Teaming and coordination between shops Inside Machine Shop Redistribute assets and capabilities to other shops Riggers Central location Improve communications with all shops Dive Shop Cluster Possible focused factory Gas Turbine Cluster Possible focused factory Diesel Shop Cluster Possible focused factory NEMAIS Needs to provide mid-process information to AWC’s Preliminary Opportunities

14. SERMC Focus - Dive Shop

15. Focused Factory - Dive Shop • FROM: • Multiple shops / Multiple handoffs • TO: • Focus the jobs into one shop that handles all the steps • Three major steps in a Dive/Pump/Valve job • Remove (Paperwork, Dam, Transportation) • Repair work • Replace (Paperwork, Dam, Transportation) • Provide the Dive Shop with the appropriate resources to handle all aspects of a Dive/Pump/Valve repair job

16. 1 2 3 4 5 6 13 12 11 10 9 8 7 Current Process for Pump/Valve Jobs Color Code Pump/Valve Shop Pump/Valve/Dive Shops Dive Shop Outside Electric Shop Riggers 15 steps and 13 passes between shops

17. Ideal Process for Pump/Valve Jobs Still 15 steps but now 0 passes between shops

18. Improved Process for Pump/Valve Jobs at SERMC Dive 1 Pump/Valve 2 Dive Still 15 steps but now 2 passes between shops • Model should be applicable regardless of whether Navy or Contractor does repair

19. Simulation of Focused Factory • Used SimCAD Pro from CreateASoft Inc. • Created model of current flows between various shops • Show gains from Physical Shop Cluster • Showed how co-location eliminates most transportation, operator motion, etc. delays • Show gains from Virtual Shop Cluster • Showed how IT and electronic communications can eliminate waiting delays due to inter-shop flows

20. SimCAD Pro Model

21. SimCAD Pro Simulation Summary

22. To Create Cell Move in 3 types of resources (~2 teams) Pump/valve mechanic Electrician Rigger Cross-train as needed Building mods as needed NEMAIS driven schedule board for Dive Shop work NEMAIS support for work as AWC Form a Green Belt Team To: 1. Product Family Matrix Done by PFAST 2. Calculate Customer Demand (Workload) Needs further refinement 3. List New Process Steps 4. Balance Workload 5. Create Cell Implementation Plan – Dive Shop

23. Gas Turbine Shop • Arm Rebuild (Mini Focused Factory) • Inside Machine Shop • Requires 1 Milling Machine • Implementation Plan • Just Do it! • Assign machine • Train personnel

24. Short Term Implement Pilot at SERMC to prove the viability of the JobshopLean concept Dive Shop Long Term Implement JSL at other Navy Repair Facilities such as: TRF NSSF Any other high-variety low-volume facility Offices How can JobshopLean Be Used by the Navy

25. 2nd Deck: Office Lean

26. 2nd Deck • Goals • Focus attention on a key and growing process • Apply Lean Thinking to remove waste • Mapped Job Hierarchy • Determined targeted processes • RCC’s/Emergent Work • MSMO • Now map the targeted processes • Realized MSMO’s and RCC’s co-exist • Focus attention on MSMO process flow (RCC included)

28. MSMO – next steps • Continued development and process improvement • Introduction to understand MSMO process • Developed functional job specific guide to move work through MSMO process • VA / NVAE / NVA analysis • Include in D-Level Repair, Maintenance, Modernization, and Closeout VSA’s

29. Questions???