Lean/Six Sigma

Presented by:
COL Alexander Raulerson
Commander, Anniston Army
Depot
 Depot Overview
 Success Story
 Path Taken
 Organizational Transformation
 Questions

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Installation Description

 1,771 Bldgs/Structures
 244 Miles of Roadway
 93 Miles of Fencing
 46 Miles of Railroad
 15,243 Acres
 $1.6 Billion Plant Replacement
Value
 $1.279B FY06 Depot Budget
 $299M FY06 Depot Payroll
 $680M Average Annual Tenant
& Contractor Budget
 6,442 Total Employees
 4,113 Depot Employees

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 ANAD Mission:

To sustain the warfighter in contact with the

enemy and support combat power reset.

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 M1 Abrams Tank M88 Recovery
Vehicle

Combat
Vehicles
STRYKER FOX Vehicle

M113 Armored M9 Armored M60 Armored Vehicle

Personnel Carrier Combat Earthmover Bridge Launcher

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Towed & Self Propelled
Artillery/Bridges

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Department of Defense
Small Arms Facility

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 AGT 1500 Turbine Engine
Success Story
 LEAN journey began Jan 03
 Improvements to date include:
 $16 M savings

 Direct labor hour requirement

reduced by 13%
 Ratio of indirect to direct personnel

drop from 8.5% to 3.6%

 Scheduled delivery from 95% to

100%
 $441K cost avoidance in tooling

 Currently working third pass

 Intense action plan

 FY06 goal – 12.5% direct labor

reduction

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Where We’ve Been…
 AGT 1500 Turbine Engine
Path Taken
 Local AFGE involvement from beginning

 Value stream analysis – 3 completed to date

 Action plan – Do-it’s … Kaizen events …
Projects

 3P (Production Process Preparation) Events

 Used to simulate extreme process changes with
high risk prior to Kaikaku
 Used for all facility modifications/ construction
 Used for all facility relocations
 Includes material presentation considerations

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 AGT 1500 Turbine Engine
Path Taken

 Partnership with Honeywell

 Began with PROSE engine
 Expanding to all engines
 Provides just in time, point of
use services
 Reduces requirement for
overhead Government
employees

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 AGT 1500 Turbine Engine
Path Taken

 Electronic Manufacturing Operation &

Tooling (EMOT) System
 Worker instructions
 Quality system
 Test procedures
 Photos
 Drawings
 Tool requirements
 Calibration data
 Process controls
 Process data capture

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 AGT 1500 Turbine Engine
Path Taken
Cell

 Flow work cell development 1-Item Std.

Flow Work
 Standard work
Basic Pull
 One-piece flow Q. Cks Sys

 6S (5S + Safety)
 Pull Visual Management

 Heijunka (load leveling) 6-S Habits

Feature by Feature Comparison

 Six Sigma projects

Product

Product

Product

Product

Product

Product

Product

Product

Product

Product
Feature

Feature

Feature

First pass yield improvements

Feature


Feature

Feature

Feature

Feature

Feature

Feature

5 5
4
3
2

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 AGT 1500 Turbine Engine
Path Taken

 Visual Management
 Supermarkets/ Kanbans

 Standard color-coded

areas
Color Codes
Material, Supplies, Consumables,
Green
Shelf Life Items, Rags, Mops
Orange Kanban, Supermarkets
Black Desks, PCs, Break Areas, Lockers A salvaged cart was modified to
Brown
Bay Area, Work Benches, Machines, create this kanban. It holds the
Presses, Etc. daily requirement of 6
Yellow Potential Hazard Areas
Fire Extinguishers, Scrap Baskets, components … provides part
Red
Chemicals protection … includes lifting
Aisles, Walkways, Transportation device on lower shelf ... Serves as
White
Lanes
Blue Reject Bays, Designated Inspection both kanban and poka-yoke

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 AGT 1500 Turbine Engine
Path Taken

 Andons
 Mail box flags
 Flashing lights

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 AGT 1500 Turbine Engine
Path Taken
 Shadowboards
 Work Station Tooling
Specific tool set for workstation requirements –
work area assigned
vs.
All tools to perform any job – employee
assigned tool set

AFTER

BEFORE
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 AGT 1500 Turbine Engine
Path Taken

 Metric boards

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Organizational
Transformation
 E EX
R IS CEL
R P L
T E GMPO EN
EN DMPO CE
DP DEQ
(Support) (Execution) (Improvement)

Vehicle Weapon Turbine Support Recip

POM POM POM POM POM
Proc Engrs Proc Engrs Proc Engrs Proc Engrs Proc Engrs
IND SPT MGR IND SPT MGR IND SPT MGR IND SPT MGR IND SPT MGR
Planners Planners Planners Planners Planners
Parts Mgrs Parts Mgrs Parts Mgrs Parts Mgrs Parts Mgrs
Matl Handlers Matl Handlers Matl Handlers Matl Handlers Matl Handlers

PROD MGR PROD MGR PROD MGR PROD MGR PROD MGR
Mechanics Mechanics Mechanics Mechanics Mechanics
Technicians Technicians Technicians Technicians Technicians

QUALITY MGR QUALITY MGR QUALITY MGR QUALITY MGR QUALITY MGR
QA Specs QA Specs QA Specs QA Specs QA Specs
Inspectors Inspectors Inspectors Inspectors Inspectors
Qual Engrs Qual Engrs Qual Engrs Qual Engrs Qual Engrs

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