The Boeing 737/757 Lean Story

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3 4 L RIGHTS RESERVED Copyright 2003, The Boeing 737/757 Lean Story Our Ship we used to build….. ALL RIGHTS RESERVED Copyright 2003, The Boeing Company Toyota Describes TPS With This Balanced House Just In Time • Lowest Cost • Highest Quality • Shortest Time Stability ALL RIGHTS RESERVED Copyright 2003, The Boeing Company Autonomation & Jidoka
5 6 L RIGHTS RESERVED Copyright 2003, BOEING PRODUCTION SYSTEM ACADEMY a.k.a. Lean Academy • OBJECTIVES: Create a cohesive, uniformly trained team centered on on an identified Value Stream based on: • o A common understanding of Lean principles • o Integrating Lean strategies into a system easily understood at every level. • o One plan for improvement • o Top management involvement • DIFFERENCE: The Academy: • § Integrates a Value Stream TEAM in BPS training and implementation implementation • § Includes Managers • § Uses powerful simulations • § Uses graduates (and ONLY graduates) as instructors and facilitators facilitators • § Gives you an implementation plan for your Value Stream Future State • § Promotes and enables linkage of Lean activities • § Culminates in a Value Stream Mapping exercise that will point to where and to what kind of Lean activity to conduct. • Excess inventory ALL RIGHTS RESERVED Copyright 2003, The Boeing Company 737/757 Traditional Factory 1965-2001 1965 2001 • Time loss during airplane line moves • Production and support groups work to different schedules and different priorities ALL RIGHTS RESERVED Copyright 2003, The Boeing Company • Tools, parts and drawings not readily available to mechanics • Production status of factory not visible • Flow time not correlated to customer demand
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The Boeing 737/757 Lean Story

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