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Lean Thinking Essay

1518 words - 7 pages

New way of Thinking and Acting for an Entire Organization

Boeing "Everett Plant" Case Study

Boeing Everett Plant, Largest Building in the World

Way of Thinking and Acting for an Entire Organization
"Definition, Purpose, Process, People"

The core idea is to maximize customer value while minimizing waste. Simply, lean means creating more value for customers with fewer resources.
A lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect ...view middle of the document...

The essence of the lean philosophy is captured in five concepts:
1. Specify value in the eyes of the customer.
2. Identify the value stream and eliminate waste.
3. Make value flow at the pull of the customer.
4. Involve and empower employees.
5. Continuously improve in the pursuit of perfection.
The ultimate goal of lean is to eliminate waste. Waste is defined as anything which adds cost without adding any value and is categorized as:
* Muda - Work which absorbs resource but adds no value.
* Muri - Unreasonable work that is imposed on workers and machines.
* Mura - work coming in dribs and drabs with sudden periods of rush rather than a constant or regular flow and unevenness.

Boeing Lean Projects Implementation

"Everett Plant" Case Study


Boeing; is implementing Lean thinking projects in various ways throughout its "Everett Plant"; it is airplane assembly building owned by Boeing. Located on the northeast corner of Paine Field, it is the largest building in the world.
The Company created an overall Lean Group to assist in the development and implementation of Lean initiatives throughout the plant. Programs invite the Group to participate in specific Lean projects if desired. The different airplane programs and organizations have also created their own Lean offices to focus specifically on Lean efforts within the particular program. For example, the 777 program has developed its own office, Critical Process Reengineering (CPR), to look for opportunities within the 777 line.

Throughout the Everett plant, Lean initiatives have yielded measurable results. Larger efforts, like some of those described below, have resulted in substantial resource productivity gains and savings. Smaller efforts have also produced significant benefits.
For example, the development and implementation of an alodine pen to be used prior to primer touch up, has reduced hazardous waste generation by approximately 36, 55-gallon drums per year. As part of a small tool recycling and reconditioning program, the 777 Wing Majors shop is recycling plastic spatulas used to apply sealant, reducing hazardous waste generation by approximately 90 percent.
Boeing Lean Efforts
To illustrate in greater detail the affect of Lean Manufacturing efforts at the Everett plant, five Lean projects were selected for closer examination. The initiatives selected and detailed below are
* The 777 Floor Grid Component Delivery Process.
* The 747 Line Side Supply and Simplified Ordering System.
* Chemical Point of Use Stations, 767 & 747 Wing Seal Moving Lines.
* The 747 Horizontal Stabilizer project.
* The 747 Horizontal Stabilizer Project has been put on hold due to technical and regulatory constraints.

These following efforts are at various stages of implementation of Lean Concept

1. 747 Line Side Supply and Simplified Ordering System
To provide better inventory control and decrease damage, the...

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