Designing Lean Value Streams for Manufacturing Growth: Success in Action. copyright 2016 Institute for Operational Excellence

Transcription

1 Designing Lean Value Streams for Manufacturing Growth: Success in Action Kevin J. Duggan, Founder, Institute for OpEx Jeff Corbin, Operations Director, Laitram Machinery

2 Renowned expert in applying advanced lean techniques to achieve Operational Excellence Author of four books on the subject Kevin has guided many major corporations worldwide, including FMC Technologies, Chromalloy, Aetna, SpaceX, Caterpillar, Pratt & Whitney, Singapore Airlines, Sikorsky, IDEX Corporation and Parker Hannifin Featured on CNN and the Fox Business Network Frequent keynote speaker, master of ceremonies, and panelist at international conferences Kevin J. Duggan

3 Operations Director at Laitram Machinery in Harahan, LA including Engineering and Production Prior Business Development Director of Qinetiq- North America s Maritime and Transportation Division 20+ years working for Lockheed Martin including as Director of Business Development at Michoud Operations M.S. of Business Administration from Tulane University B.S. in Chemical Engineering from University of Missouri Jeffrey M. Corbin

4 Operational Excellence Case Study: Laitram Machinery Kevin J. Duggan

5 Operational Excellence Companies have done continuous improvement activities for years

6 Continuous Improvement Pareto

7 Impact Continuous Improvement Effort

8 Continuous Improvement

9 Improving Operations

10 Improve Improve Improve Sustain Sustain The Lean Journey Eliminating Waste Sustain

11 Level of improvement Operational Excellence Mature lean company Time in Years

12 Level of improvement Operational Excellence Operational Excellence Time in Years

13 Level of improvement Operational Excellence Operational Excellence Time in Years

14 Operational Excellence When each and every employee can see the flow of value to the customer, and fix that flow before it breaks down. SM Kevin J. Duggan

15 Self-healing flow Autonomous delivery Operational Excellence Repeatable operations without management intervention Operations management working upfront with sales and marketing Operations management part of the innovation funnel, the customer experience, the customer solution, and technology breakthroughs

16 Normal vs. Abnormal Flow Normal Abnormal

17 Normal vs. Abnormal

18 The Offense Meter

19 The Eight Steps to Achieve Operational Excellence Design a lean flow using lean guidelines. Implement a lean flow. Make the lean flow visual. Create standard work for the lean flow. Make abnormal flow visual. Create standard work for the abnormal flow. Teach employees to maintain and improve the flow to the customer. Free management to work on offense.

20 Business Growth at Laitram Machinery Jeff Corbin

21 Laitram Machinery Manufacturer of seafood processing equipment Headquartered in Louisiana 1,500 employees worldwide (Laitram LLC)

22 Saw Kevin Speak at Fabtech Visited Hypertherm Laitram Machinery Understood the difference between endless journey and setting a destination Received training and guidance in mfg and office Followed eight principles of OpEx

23 Laitram Machinery Designed value stream flow Implemented flow Standardized the flow Engaged the workforce to see and understand flow Workforce now sees and understands abnormal flow

24 Laitram Machinery Manufacturing Speed of progress once normal vs. abnormal understood. Employees understanding of and reaction to color-coded flags.

25 OpEx Concept Spread to Supplier Laitram Machine Shop (sister company and supplier to Laitram Machinery) also adopted these concepts in their machine shop and office

26 Laitram Machinery Manufacturing and the Office Manufacturing employees now know if quoting is on time in the office very unique Quote turnaround speed affects business growth

27 Laitram Machine Shop Office Complete quotes in process one, move one fashion. Guaranteed turnaround time for quotes. Laitram machinery gets their quotes and information on time.

28 Laitram Machinery Business Growth Understand normal vs. abnormal Self-healing flow Autonomous delivery to the customer Leadership now has time to focus on business growth

29 Installation review in Norway Salmonella outbreak among pistachios in California Working on Offense Business Growth

30 OpEx principles Application in Food Industry Internal Supplier Leading to Business Growth Level of improvement Operational Excellence Operational Excellence Time in Years

31 Kevin J. Duggan Jeffrey M. Corbin Questions?

32 Live Training Events Each year the Institute for Operational Excellence producing training events throughout the U.S. and Europe. Orlando, FL January 30 February 1, 2017 Orlando, FL February 2, 2017 For more information please visit