Applications of Lean Ideas to the Aerospace Industry

• Lean Aerospace Initiative origin and mission • Functional lean successes • Successes through interaction between functions • Success through enterprise integration and value creation • Total enterprise integration of all stakeholders • Enterprise transformation insights

Benefits of Implementing Lean Practices and the Impact of the Lean Aerospace Initiative in the Defense Aerospace Industry and Government Agencies

In the 1980’s, many United States industrial organizations started developing new production processes to improve quality, reduce cost, and better respond to customer needs and the pressures of global competition. This new paradigm was coined Lean Production (or simply “Lean”) in the book The Machine That Changed The World published in 1990 by researchers from MIT’s International Motor Vehicle Program. In 1993, a consortium of US defense aerospace firms and the USAF Aeronautical Systems Center, together with the AFRL Materials and Manufacturing Directorate, started the Lean Aircraft Initiative (LAI) at MIT. With expansion in 1998 to include government space products, the program was renamed the Lean Aerospace Initiative. LAI’s vision is to “Significantly reduce the cost and cycle time for military aerospace products throughout the entire value chain while continuing to improve product performance.” By late 1998, 23 industry and 13 government organizations with paying memberships, along with MIT and the UAW were participating in the LAI.

Lean Enterprise Self-Assessment Tool (LESAT)

-Status report on June Executive Board commitments -Enterprise-level LESAT Beta Version -Detailed-level LESAT Development Plan -Industry and government participation and support requirements -Resource Needs -Executive Board decision on proposed next steps

Lean Enterprise Transformation: Measuring and Accelerating the transition to lean.

PowerPoint presentation that showcases: • Research Objectives • Strategic Value of the Lean Enterprise • Multi-Stakeholder Value Optimization • Lean Enterprise Self-Assessment Tool (LESAT) • Leading and Lagging Indicators of Lean Enterprise Transformation • Empirical Results in the Aerospace Industry • Accelerating the Lean Transformation - Linking LESAT to Strategic Objectives • Summary and Questions

Lean Transition of Emerging Industrial Capability

This volume of the final report documents the technical work performed from December 1998 through December 2002 under Cooperative Agreement F33615-97-2-5153 executed between the U.S. Air Force, Air Force Research Laboratory, Materials and Manufacturing Directorate, Manufacturing Technology Division (AFRL/MLM) and the McDonnell Douglas Corporation, a wholly-owned subsidiary of The Boeing Company. The work was accomplished by The Boeing Company, Phantom Works, Huntington Beach, St. Louis, and Seattle; Ford Motor Company; Integral Inc.; Sloan School of Management in the Massachusetts Institute of Technology; Pratt & Whitney; and Central State University in Xenia, Ohio and in association with Raytheon Corporation. The LeanTEC program manager for AFRL is John Crabill of AFRL / MLMP and The Boeing Company program manager is Ed Shroyer of Boeing Phantom Works in Huntington Beach, CA. Financial performance under this contract is documented in the Financial Volume of the final report.

Strategies for Lean Product Development

The essence of lean is very simple, but from a research and implementation point of view overwhelming. Lean is the search for perfection through the elimination of waste and the insertion of practices that contribute to reduction in cost and schedule while improving performance of products. This concept of lean has wide applicability to a large range of processes, people and organizations, from concept design to the factory floor, from the laborer to the upper management, from the customer to the developer. Progress has been made in implementing and raising the awareness of lean practices at the factory floor. However, the level of implementation and education in other areas, like product development, is very low.

The Wrong Kind of Lean: Over-Commitment and Under-Represented Skills on Technology Teams

This paper reports on results from five companies in the aerospace and automotive industries to show that over-commitment of technical professionals and under-representation of key skills on technology development and transition teams seriously impairs team performance. The research finds that 40 percent of the projects studied were inadequately staffed, resulting in weaker team communications and alignment. Most importantly, the weak staffing on these teams is found to be associated with a doubling of project failure rate to reach full production. Those weakly staffed teams that did successfully insert technology into production systems were also much more likely than other teams to have development delays and late engineering changes. The conclusion suggests that the expense of project failure, delay and late engineering changes in these companies must greatly out-weigh the savings gained from reduced staffing costs, and that this problem is likely going to be found in other technology-intensive firms intent on seeing project budgets as a cost to be minimized rather than an investment to be maximized.

Applying the Lessons of “Lean Now” to Transform the US Aerospace Enterprise

Lean is common sense and good business sense. As organizations grow and become more successful, they begin to lose insight into the basic truths of what made them successful. Organizations have to deal with more and more issues that may not have anything to do with directly providing products or services to their customers. Lean is a holistic management approach that brings the focus of the organization back to providing value to the customer. In August 2002, Mrs. Darleen Druyun, the Principal Deputy to the Assistant Secretary of the Air Force for Acquisition and government co-chairperson of the Lean Aerospace Initiative (LAI), decided it was time for Air Force acquisitions to embrace the concepts of lean. At her request, the LAI Executive Board developed a concept and methodology to employ lean into the Air Force’s acquisition culture and processes. This was the birth of the “Lean Now” initiative. An enterprise-wide approach was used, involving Air Force System Program Offices (SPOs), aerospace industry, and several Department of Defense agencies. The aim of Lean Now was to focus on the process interfaces between these “enterprise” stakeholders to eliminate barriers that impede progress. Any best practices developed would be institutionalized throughout the Air Force and the Department of Defense (DoD). The industry members of LAI agreed to help accelerate the government-industry transformation by donating lean Subject Matter Experts (SMEs) to mentor, train, and facilitate the lean events of each enterprise. Currently, the industry SMEs and the Massachusetts Institute of Technology are working together to help the Air Force develop its own lean infrastructure of training courses and Air Force lean SMEs. The first Lean Now programs were the F/A-22, Global Hawk, and F-16. Each program focused on specific acquisition processes. The F/A-22 focused on the Test and Evaluation process; the Global Hawk focused on Evolutionary Acquisitions; and the F-16 focused on improving the Contract Closeout process. Through lean, each enterprise made many significant improvements. The F/A-22 was able to reduce its Operational Flight Plan (OFP) Preparation and Load process time of 2 to 3 months down to 7 hours. The Global Hawk developed a new production plan that increases the annual production of its Integrated Sensor Suite from 3 per year to 6 per year. The F-16 enterprise generated and is working 12 initiatives that could result in a contract closeout cycle time reduction of 3 to 7 years. Each enterprise continues to generate more lean initiatives that focus on other areas and processes within their respective enterprises.

Lean Transition of Emerging Industrial Capability (LeanTEC)

Lean Transition of Emerging Industrial Capability (LeanTEC) program was a cooperative agreement between the Boeing Company and AFRL conducted from January 1998 to January 2002. The results of this program are documented in the Manual for Effective Technology Transition Processes included as an attachment to this report. This manual provides processes, procedures, and tools for greatly improving technology transition in the aerospace industry. Methodology for the implementation of these improvements is given along with methods for customizing the various processes, procedures, and tools for a given company or business unit. The indicated methodology was tested by the LeanTEC team and results are documented in the report.

Que lean y se sientan felices.

Resumen tomado de la publicación

Pasen y lean.

Los alumnos de primer ciclo de educación secundaria, en general, poseen un déficit de las destrezas lecto-escritoras. Por ello, este proyecto pretende reconvertir el aula en un espacio donde se fomente la lectura y la escritura y se traten, individualizadamente, las necesidades educativas de los alumnos; al mismo tiempo que realizan actividades colectivas. Entre los objetivos específicos se encuentran establecer un repertorio de lecturas básicas; atender las necesidades específicas de los alumnos que no tienen el español como lengua materna; potenciar la producción de textos por parte de los alumnos, y desarrollar su expresión oral; además, se potencia el carácter científico-lúdico de la ortografía. Se plantean varias actividades como la lectura colectiva de textos, realización de resúmenes, transformaciones de textos, o concursos de redacción. Para la realización de todas estas actividades se realiza una selección de obras de literatura infantil y juvenil de diferentes editoriales. Se adjunta el listado con la selección de lecturas.

Para que lean viviendo.

El proyecto persigue que los alumnos de primer y segundo ciclo de Primaria y quinto de EGB obtengan un mayor dominio del lenguaje y de la lectura, base fundamental de todo aprendizaje significativo futuro. Los objetivos son: desarrollar la comprensión lectora; aumentar la capacidad de lectura eficaz; despertar el gusto por la lectura; expresar, de forma escrita, los propios pensamientos; potenciar la capacidad creativa; utilizar los textos escritos por los niños como soporte de lectura entonativa; y capacitar al niño para escribir narraciones y juegos dramáticos. La metodología utilizada es la que en Francia desarrolla la asociación para la investigación y aplicación de la lectura. El proceso consiste en la selección de un libro utilizado cada trimestre como base para los distintos juegos de lectura. Además realizan otros ejercicios (salto de ojo, percepción rapida, vocabulario, ortografía, etc.). Los alumnos participantes en la experiencia son voluntarios y las sesiones se realizan en horas extraescolares. Se constata así que los alumnos comprenden mejor y que ha aumentado la eficacia de su lectura, siendo necesario continuar con el proyecto.

Estudi i implantació del sistema Lean Manufacturing a una empresa convencional del sector de l'automòbil, per incrementar la competitivitat

El projecte es planteja la implantació de la metodologia LEAN en una de les plantes de producció d’una empresa del sector de la indústria de l’automòbil per aconseguir millorar la seva competitivitat. El projecte engloba l’anàlisi de les cadenes de valor de quatre dels productes més significatius que es fabriquen actualment a la planta, mitjançant la metodologia Value Stream Map (VSM), així com el desenvolupament de noves propostes per la millora de cadascuna de les cadenes

Adopción de políticas Lean supply chain en la cadena porcina en Cataluña

Después de Alemania, España es el segundo mayor productor de cerdos entre los 25 países de la Unión Europea. El consumidor tiene una importancia relevante debido a la tradición cultural del consumo de carne, reflejada en la gastronomía de todas las regiones de España. Cataluña forma parte de las seis regiones Europeas más productoras de cerdos y representa aproximadamente un tercio de la producción Española. El presente trabajo analiza las características y comportamiento de varios agentes que conforman la cadena de abastecimiento porcina en Cataluña, con el objetivo de valorar si estas operan de acuerdo a los parámetros de una cadena de abastecimiento Lean. Inicialmente un modelo de cadena Lean se propone como herramienta para llevar a cabo la valoración. Los resultados llevan a determinar si la situación en la cadena porcina Catalana se asemeja a una cadena tipo Lean.

Requirements for building information modeling based lean production management systems for construction

Smooth flow of production in construction is hampered by disparity between individual trade teams' goals and the goals of stable production flow for the project as a whole. This is exacerbated by the difficulty of visualizing the flow of work in a construction project. While the addresses some of the issues in Building information modeling provides a powerful platform for visualizing work flow in control systems that also enable pull flow and deeper collaboration between teams on and off site. The requirements for implementation of a BIM-enabled pull flow construction management software system based on the Last Planner System™, called ‘KanBIM’, have been specified, and a set of functional mock-ups of the proposed system has been implemented and evaluated in a series of three focus group workshops. The requirements cover the areas of maintenance of work flow stability, enabling negotiation and commitment between teams, lean production planning with sophisticated pull flow control, and effective communication and visualization of flow. The evaluation results show that the system holds the potential to improve work flow and reduce waste by providing both process and product visualization at the work face.