Factory Building Symposium on Lean Production

Factory Building Symposium on Lean

Production

January 29, 2007Austin, Texas

Management Commitment

Southern Energy HomesAddison, ALLamar Dickerson, Director of Lean Manufacturing

Southern Estates Plant Started: 1982 Location: Addison, AL Home type(s): HUD Code Price point: Moderate Design: Some

customization Production: 5 to 6

floors/day Market area: Southeast US

Material Flow Work Space Conveyance Quality Information flow

Organization and new hoist relieve strain and speed productionOrganization and new hoist relieve strain and speed productionMaterial not close to point of useMaterial not close to point of useProduct flow rationalizedProduct flow rationalizedNo error proofingNo error proofingJigs help maintain qualityJigs help maintain qualityConfusion leads to production of wrong partsConfusion leads to production of wrong partsRacks and labeling systemRacks and labeling system

Interior Wall Build

Congestion slowed workCongestion slowed workVisibility across workstation promotes visual managementVisibility across workstation promotes visual managementLots of totingLots of toting

Then Now

Results Production on target Reduced from 9 to 6.5 people Re-assigned workers to other departments Space reduced by 12% Wallboard damage reduced 10% One-time cost of RPI: $25,786 Annual labor savings of $73,200 plus the

savings of not needing to hire and train 2.5 workers

Highlights Wide range of RPI

participants All key people present Strong support of plant

management Morale in wall

department very high

Management Commitment Dedicated director of

lean Permit teams to take

time Invest in the changes Take workers

seriously Senior manager

involvement

Going forward Spread lean

company-wide Management

workshop Lean teams Plants required to

conduct lean activities

Lean Symposium

Manufactured Housing Research AllianceJordan Dentz

(212) 496-0900 [email protected]

www.mhrahome.org

Factory Building Symposium on Lean

Production