ELT 1999-2000 Action Plan

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ELT 1999-2000 Action Plan Powered By Docstoc
					    F22 Raptor
Lean Manufacturing
                  F-22 Lean


• Concept
  – Why Lean?
  – What does it mean?
• Progress To Date
  – Boeing
  – LM Ft Worth
  – LM Marietta
• Challenges
                              2
            F-22 Lean: The Concept

 • Why?
   – To save the program money
   – To save the industrial base
   – (To save the program)
 • What is it?
   – Mindset, cultural change
   – Common sense, real means to improve
   – AIWs, Kaizens, Kaikakus, TOC, 6 Sigma, etc
      • And everything Snod said

F-22 Can Be More Affordable Through Lean
                                             3
                  F-22 Team Responsibilities




                                                 Lockheed
   Boeing           Lockheed Fort Worth    Aeronautical Systems
Aft Fuselage       Mid Fuselage           Forward Fuselage
Engine             Electronic Warfare     Edges
Integration        Communication/Nav/     Horizontal Stabilators
Wings              Identification         Vertical Stabilizers
Radar              Vehicle Management     Mate & Final Assembly
Mission            System                 Weapon System
Software           Support System         Integration
Training System                           Common Integrated 4
                                          Processor
                                               Boeing Lean
                                           Engine Bay Doors AIW


      Lean Implementation                                                     Lean Results
 F-22 Lean Event - Boeing/BF Goodrich
 Goal:     Develop optimum operation for the F-22 Engine Bay                Cost History
           Door and Lay-up and Bond Preparation Cell
                                                                               9/97
Results:   • 34% reduction in cycle time (56 vs. 37 days)                      3/98
           • 43% reduction in manufacturing cost
           • 28% reduction in floor space                                      6/99
           • 25% reduction in staffing
           • Point of use tooling implemented                                  3/00
           • Future events planned
                                            After




                                                               Cum Cost $
           Before Event
                                                                                                   33% Cost
                                                                                                   Reduction!


                                                                                           Units




                                                                                                         5
                 Fort Worth Lean
Blitz events in 2000
  – Mate Longeron Installation (Build Team)
     • Operator travel reduced 84%
     • Span time reduced 50% (from 6 to 3 M-days)
     • Touch labor reduced 47%
  – Tool Trial Run (Airframe / Production Control)
     • Span time reduced 95%
     • Tools tracked and scheduled in MRP
     • Eliminates post inspection tasks
  – Module 4 Upper Surface (Build Team)
     • Optimize workstation design and layout
     • Conducted 19-26 June

                                                     6
Mid Fuselage Bore Fixture




                            7
          Current Process - Bore Fixture

• Process Baseline was 14 M-days
  – Boring/Spotfacing - 3 days
  – Hinge Installation - 11 days
• Boring must be complete prior to
  working hinges on structure
• Two fixtures required to meet planned
  rate
• Boring/Main Weapons Bays Hinges on
  critical path for Mid Fuselage

                                          8
                Area Layout/Workstation




COFX Detail Tool Install             MWB Structure Drill




                           MWB Small
                           Hinge Shim and
                           Drill
                                                           9
                            Current Layout
Community Tools          Community Tools     Shim Area (200 Ft).




                                                Air Hose Tree




Bushings

                                 Bob Knobs

                                                              Air Hose Storage
            COFX Tools




                                                                   Operating
                                                                   Supplies      10
                                  New Area Layout/Workstation



                                    R1          R2
        Surface Prep
           MWB




                                                           MWB Worktable/
                         PLS
Admin




                                    A-R                    Workcart
                                          B-R        C-R   SWB Worktable
                                                           Detail Storage
                                          B-L        C-L
                                                           MWB Platform
        Pre-Drill




                                    A-L
         MWB




                                                           SWB Platform
                                                           Wall
                                                           Add Air
                                    L1          L2

                       Sand Saw

                                                                    11
                                                    Bore Fixture
                                               Process Improvements
                                                                                                                    7122
  Position                                     1836

                                                                                   4772
Manual Op                        1029

                                                                     3366
     Walk               409

                                                                    3304
    Tools                  596

                                                      2346
    Other                               1419

                                 1031
   Inspect       60

                     199
     Load        0

                  150
    Parts        34                                                                                 As-Is Time

             45
                                                                                                    Improved Time
   Unload
             0                                                                            Time is only for tasks videotaped
             27                                                                           and analyzed and does not
Mtl Handle   0                                                                            represent entire Bore Fixture tasks

             0                1000             2000          3000           4000   5000           6000         7000         8000

                                                                    Time (secs)                                                 12
                      Bore Fixture
                 Reduction in Cycle Time
12
                         Baseline Process
                         New Process

10


8


6


4


2


0
     1   2   3   4   5   6     7         8   9   10   11   12   13   14
                                   Day
                                                                          13
                                     Leaning F-22 Final Assembly
  • ACHIEVE FULL PRODUCTION RATE (38 AIRCRAFT / YEAR)




FUNCTIONAL TEST EQUIPMENT             ENG PARK     TOOL PARK                TOOL PARK
                                                                                                           STAGING
                                                                                                                             S.C.   M.C.
                                                                                                          & STORAGE


                                                                                                                          200 P/U / RTP
                                                                                                                           4124               4126
                                                                                                               BR




                                                                                                                                                         TOOLS
                                                                                                                                              200
                                                                                                                          RTP / 200 P/U
                                                                                                                                              FAJ
                                                                                                           ASB
   4116        4117         4118       4119          4120           4121          4122                     280

                                                                                                                           4123              4125
              S.C.          CLASS.    FUNCT.                     F.F.
                                                     S.C.
                            PARTS     TEST
                                                                                  225 225    220         220        220       220
                                                                           226                                                        210 210 210
                                                                                  FAJ FAJ    FAJ         FAJ        P/U       P/U                   BR



                                                                                                   223
                                                      STD TOOL
                        V. STAB.                          &                        S.C. BR         224     S.C.
    ASB 820                              OFFICES                        ASB 230                                     BR         HARNESS & CONSOLE ASSEMBLY
                       L.E. INSTL.                   TOOL INSP
                           529




                                                                                                                                                         14
                                   Fwd Fuselage
                                Build Improvements
                                     Storage racks for POU
Overhead utilities improve           alignment tools
                                                              Work / storage tables provide
safety and improve quality by        eliminates walking for
                                                              locations for all parts and kits
providing light, air,vacuum,         retrieval and storage
                                                              needed to perform work in
electricity right where it’s                                  area.
needed.




                                                                                     15
                 Challenges


•   Visionary Leadership
•   Middle-management (IPT) buy-in
•   Cultural Change
•   Supplier Partnerships (e.g. LM-Boeing)
•   Leaning out Suppliers

       Supply Chain Must be Lean
          from Top to Bottom
                                             16
                                                   One Challenge Ahead
                            Alliant TechSystems               Electrodynamics           Honeywell     NWL                    Interval
                            Kaman                             HamiltonSundstrand        Rosemount     Global Tooling         Hughes Treitler
            Boeing          MPC                                                                       Models & Tools         Amphenol Bendix
                                    Supplier Content as % of Contract Value                           M. C. Aerospace
                                                                                                                             BFG/Simmonds
Dowty Decoto      100   %                                                                                                    GD Armament
Primex
                                                                                                                             Sanders
Schlosser          90                                                                        Argo-Tech                       Fenwal Safety Syst
Timet Castings                                                                               Crane/Lear Romec
                                                                                                                             Litton Itek
Aerojet            80                                                                                                        Wyman Gordon
Aircraft Eng
Avica              70                                                                                                     Pratt & Whitney
Chem-Tronics
                                                                                                                         Boeing Defense
Circle Seal        60                                                                     70%
Eaton                                                                                                                    GKN Westland
Hexcel                                      60%                      61%                 Pratt                           Hamilton Sunstrand
                   50
Honeywell                                                           Boeing                &
                                       LM Aero                                          Whitney                                  F-22 SPO
Kaiser             40
LM Aero - Palmdale                                                                                                      EDO
                                                                                                                        Lucas Aerospace
Litton             30
BAE Systems                                                                                                             Curtiss Wright
                                                                                                                        Hexcel, AlliedSignal
Marvin Eng         20                                                                                                   Smiths Ind.
OEA Aerospace
Pacific Scientific 10                                                                                                   Northrop Grumman
Parker Bertea                                                                                                           Orbital Sciences
Parker Hannifin    0
Raytheon                        Honeywell                                                                        Brunswick, Walter KIDDE
BF Goodrich (Rohr)              Motorola                                                                         Howmet, Alliant TechSystems
Sierracin/Sylmar                                                                                                 BAE Systems
Sterer                                    Menasco                             Vickers                            Harris
Superform USA                             Raytheon Training                                                      Intellitec
Sweeney Eng                               Raytheon TI                                                            LMEM
Symetrics                                 ICI Fiberite  LMAero                          LM Aero                  Pall Aero   BAE Systems
Telair Int’l                                          Ft. Worth                         Marietta                 Trilectron Avionics - UK
Teledyne                                                                                                                     Helmet Integrated
Vickers                                                                                                                      Systems - UK
TRW
                        GOAL: A LEAN, MEAN SUPPLIER BASE                                                                       Normalair Garrett-UK
                                                                                                                               Kidde Graviner
                                                                                                                                     17
                                                                                                                               Ltd - UK
                        Lean Deployment 2000 Master Schedule
                           1999 2000
                                    Qtr 1       Qtr 2       Qtr 3       Qtr 4
                        Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Hamilton Sundstrand

BAE Systems
(Santa Monica CA)                       X
Aerospace Avionics
GKN Westland
(East Cowes, England)                                 X       X         X
                                       <moa>
BAE Systems
(Rochester, England)                                          X         X
Hawker de Havilland                     X             X       X         X
TRW                                                   X
Raytheon
(Plano/McKinney TX)
Honeywell
(Torrance CA)
Flight Dynamics
Northrop Grumman
(Baltimore)
                                                          Engagement/
                                            Symbols       Baseline
                                                                              Kaizen Event         18
                                                                                                   Drop-In Activity
                                                                                             Jun
                                                                                                   Slipped Schedule
                                            Status        Original Schedule   Completed            w/ Original month
                      Lean Deployment 2000 Master Schedule
                         1999 2000
                                  Qtr 1       Qtr 2       Qtr 3       Qtr 4
                      Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Cytec Fiberite
(Anaheim CA)
Harris
(Melbourne FL)
Sargent Fletcher
Curtiss-Wright
Alliant Techsystems
Honeywell
(Albuquerque NM)
Aerostructures
Aerotec
Parker Hannifin
(Irvine CA)
Smiths Industries
(Grand Rapids MI)
Simmonds Precision
Rosemount

                                                  Engagement/
                           F-22         Symbols   Baseline
                                                                      Kaizen Event         19
                                                                                           Drop-In Activity
                                                                                     Jun
                                                                                           Slipped Schedule
                                        Status    Original Schedule   Completed            w/ Original month
             Summary/Lessons Learned
• Lean Implementation Continues to be Successful
   – $200+ M in Documented Savings to Date
   – Will yield $2-4B in Program Production Savings –
                or else!
• Most Successful Applications/Events are IPT Created
   – Pushing Lean on IPT’s Hasn’t worked
   – Need IPT’s to PULL Exec Lean Team Involvement
• “Need Leadership to Help Create Environment that Will
  Cause IPT’s to Have Ownership in Implementing Lean”
• Suppliers must be Leaned Out

             Leadership Challenge:
     Lead Horse to Water…. Make Him Thirsty
                                                        20

				
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