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Show Hilltop Times July 14, 2005 Leaning ahead Workers finish project in half the time BYBILLORNDORFF 309th Maintenance Wing While the Ground Systems Repair Section has used Lean principles in the past, a January project guided by Lean from start to finish ended up being completed in half the time it normally would have taken. The section, part of the 309th Maintenance Wing's 309th Missile Maintenance Group, refurbishes trailers used to transport Peacekeeper missile warheads and guidance packages to launch 309th Missile sites. The preventive mainteMaintenance nance, done every Group seven to 10 years, has taken 110 days in the past, counted from the time the section first received the transporter until the finished product was given its final road test. This time, the work was finished in 56 working days. Work began on Jan. 24, with a projected completion date of April 20. Instead, the job was finished ahead of schedule on April 12. "One thing that's important in our business is getting the customer— the people at the missile site — their equipment quickly and in superior quality," said John Grubb, section chief. "These equipment items are very limited. It's important that when the customer releases the equipment to the depot, the depot needs to work smart and turn it around quickly, so the customer doesn't have to wait very long." Work involves refurbishing the transporter from the wheels up — a job that involves removing parts and cleaning off corrosion, replacing parts that have broken or cracked, and painting the vehicle to a "like new" condition. "The vehicle comes in, just like you see it rolling down the road, and the only thing that doesn't come out of here is the engine and transmission," said heavy mobile maintenance mechanic James Lee. Star Sipangltd Sewings "Everything else is removed, cleaned, repaired, sandblasted, repainted, replaced, whatever we need to get the job done — all the way from the cab to the end of the vehicle and everything in between." "It's interesting, the condition that some of these trailers come in," Mr. Grubb added. "Some of these trailers are stationed at Vandenberg AFB and they have a real corrosion issue, since they are next to the ocean. We have to deal with the corrosion issues while the asset is here for depot maintenance. Not only do we have to deal Photo by BIN Orndorff with corrosion, but we also have to make Heavy Mobile Maintenance mechanics Kevin Clark, James Lee and Derrek Walley work on the tractor of a modifications and repair any damage. missile transporter In the Ground Systems Repair Section. The shop is part of the 309th Missile MainteOne trailer came in with extensive damnance Group and recently used Lean principles to increase production, quality and efficiency. Areas In the age to the front end, so we were able to background are marked and painted to keep ladders, file cabinets and other items organized. incorporate some of our Lean techniques so we could stay on time with the repair around deciding what we should do, but but are making the same effort as before. processes." the mechanics — actually the person who "We've got four vehicles in here in four Lean principles entered the process touches it last — really knows best what's different stages of repair," Mr. Maw said. when section employees from different going to be beneficial to the end item," Mr. "We keep the crews busy — they're workshops and organizations were trained by Lee said. "Lean gives the opportunity, a ing smarter, but not harder. Just as before, a contractor. voice to the mechanic or to the sheet metal you try to put out a product and you can person, whoever it is that's involved. only work so hard on it, otherwise you "They taught the group — walked them through the value stream mapping pro"They've had these ideas for years but start having problems with doing the job cess. They then taught the team to build never a way to implement them. This gives right. I think we put out a pretty good a standard worksheet chart that defines them a forum to say 'you know I've thought product. what work needs to be accomplished and "I always maintain that if you have a about this for years — I don't know why we when the didn't use choice between a schedule to meet and work is to be this idea quality, I'd rather meet the quality than completed," ago, years the schedule. If you don't have the qualhey've had these ideas but we can ity there Mr. Grubb and have the rework drawn on it, said. really implethen you've defeated the purpose of havfor years, but never Changes ing a schedule. You've got to do quality to ment those made as a begin with." things.' It a way to implement result of gives them Completed work goes through an inspecthe Lean a forum, tion, based on 20th Air Force standards. them" process in"In the past, 20th Air Force would come — James Lee a place to clude: down and we did a shoulder-to-shoulder speak their • C overvoice. We're acceptance inspection with them," Mr. ing the " ~~~ finding they Grubb said. "Often, we would call them to had the idea floors and arrange the inspection, then had to wait painting the walls to give the work areas but not a way to express it." two weeks for them to get their orders While some employees were skeptical at more light. and come down here. After they did their first, thinking the program was one that inspection and we corrected the write-ups • Saving time by placing three or four mechanics on the job at one time and would come and goin a few years, most they found, we'd finally transfer the trailer working in areas that didn't conflict with are seeing the benefits of Lean in the proto the missile site. That process in itself, duction rates and cost savings. done after the trailer was completed, was each other. taking four to six weeks. • Giving the employees the tools needed "I think Lean is incredible. It's added in individual toolboxes a lot of benefits to our building, things "We obtained a copy of their inspection to cut down on travel that we can use," Mr. Lee said. "Obvichecklist and now use it as part of our pretime to a centralized ously, you're not going to change things inspection. Once we used it, our section tool area. overnight. Lean is an ongoing process. findings decreased until 20th Air Force You're continually looking for ways, not finally said 'we're happy with your quality • Getting rid of unneeded equipment and to cut corners, but to make things more control — we're not coming any more." We fixtures to free up workreduced another step that was in addition efficient. space. to the 110 days." "For example, a vehicle we worked on previously, we would pull a part off and • Stocking items such From planning to completion, the job as air conditioners and it would sit here for a whole month while was a team process, Mr. Grubb noted. environmental doors to we waited for the paint shop to get the "It's not just the mechanic on the floor eliminate the wait for other portion done. Now, sheet metal can — it's the planners, the schedulers, supparts. do their side of the job while it's being ply folks — they all have to be involved, • Using "6S" prinpainted — we don't have people standing they all have to look at their processes to ciples — "safety, sort, around waiting for something to be done. support people on the floor," he said. "If their processes aren't going to work, we're straighten, shine, stanIt gives us an order in which to do things so we can find areas that are going to be not going to meet our goals. By the time dardize, sustain" — to you look at mechanics, sandblasters, sheet create an orderly workmost beneficial to us." place. metal, everybody, you're looking at 20 to Neal Maw, a mechanic who has worked "The key to Lean is 25 people to make this happen just within for the squadron for 15 years, finds that not somebody sitting this building." employees have changed a few processes. 15% OFF When you present your base Identifaction Offer expires 8-31-05 "Some restrictions apply * See store for details Imjfrediate Openings in the Following Career Fields: I ^_^ 460 S. 200 W. (Exit 320) BOUNTIFUL, UT Hours M-F 9 am - 6 pm Sat. 9:30 am - 5 pm 'A 4 unai*adio2Ei TSgt. Bensori SSaUMcGinnis > Satifrite Midland 2E1> »•> Vehicle Mainterianfi & Communicltions'Efigineer 33Sgi i (801) 298-1878 underpargolfutah.com ;4 AIRNATIONALGU/ Base Restaurants Ext. 7-2043 Menu Line, Ext. 7-1192 |