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Show 10 TIMES 1573rd Aircraft Maintenance Squadron [competes for prestigious Shingo Prize June 8, 2006 accept a new A-10 Thunderbolt II pylon workload. It continues to meet production with a 100 .. The men and women of the 573rd Aircraft percent on-time delivery rate to its warfighting j Maintenance Squadron, part of the 309 Maintecustomers. i nance Wing, will represent the Ogden Air LogisAlso earning 2005 awards were Warner Robins .' tics Center as Shingo Prize inspectors visit next ALC who garnered the first Shingo Public Sec' week. tor gold award for its C-5 Programmed Depot Maintenance; and Oklahoma City ALC which i- A team of seven Shingo examiners, who are earned a silver award for refurbishing its depot • executives from Boeing, the HON Company maintenance for the Air Force's KC-135 Strato'and other corporations, will spend June 14-16 tanker force. inside the squadron's operations analyzing data to support the 573 AMXS claims of continuous Using lessons learned process improvement efforts that have resulted Relying on the lessons learned from the 2005 in positive bottom-line gains. Their findings Shingo Prize examination, many of the same [will then be scored and submitted with award key workers within the 573 AXMS are guiding I recommendations to the Shingo Prize board of their fellow employees in this round of highly int directors. Final results will be announced in tense competition. jjuly and the awards presented at the Public SecThe Shingo Prize for Excellence in Manufac! tor Shingo Conference in early September. turing competition recognizes and awards sites f "The entire squadron is competing for the | prize this time," said Robert Hall, F-16 Squadron that can demonstrate they have achieved draI director. "This is an incredible undertaking. The matic performance improvements. Hill AFB employees have worked steadily to \ squadron's value stream includes more than.900 f employees and dozens of backshops and support prepare for the upcoming challenge competition and are expecting a rigorous verification and agencies who have come together to enter this validation examination of their production and competition. Challenging for the Shingo Prize at the squadron level has been a valuable experi- support area processes. According to Dr. Chalon Keller, deputy chief, ; ence for everyone and we're ready!" The award, often referred to as the Nobel Prize Ogden ALC's Transformation Division, "Be1 , of manufacturing for organizations, set the stan- cause of the 573 AMXS significant efforts in dards for many public and private organizations Lean and Process Improvement activities over the last three years, which include the complete involved in industrial or manufacturing efforts. cellularization of all their pro"Challenging for the 2006 duction processes, the squadShingo Prize for Excellence ron's leadership decided to : in Manufacturing in the pubchallenge for the prestigious lic sector category and at the and world-renown Shingo squadron level is an ambiThe Shingo Prize is directPrize." tious undertaking in anyone's ed by a board of individuals She said efforts to establish a book," said Maj. Gen. Kevin who are leading representacellular flow capability began J. Sullivan, Ogden ALC comtives of businesses, profesin February 2004 in earnest mander. "This is yet another sional organizations, and when concerns arose over opportunity our employees academic institutions. The the number of F-16 aircraft take on every day to demaward is named for Japaworldwide waiting in depots onstrate what it takes to 'Be nese industrial engineer Dr. for maintenance at any given America's Best.'" Shigeo Shingo who distintime. To compete for the prize, guished himself as one of organizations must clearly Targets, timelines and goals the world's leading experts demonstrate they promote were established by members in improving manufacturing of the 573rd Aircraft Mainteworld-class manufacturing processes. Dr. Shingo has nance Squadron and put into strategies and practices that been described as an "engiachieve world-class results. action as a way to speed proneering genius" who-wrote "I am proud of each of the duction and reduce the time about and helped create aircraft remained men and women in the squadout of the many aspects of the revoluhands of the operational units. ron because what they've tionary manufacturing prac"A complete Value Stream challenged themselves to do, tices which comprise the Map analysis of the squadron is to go after the award as a Toyota Production System. enabled the creation of stanteam. They'll be opening up their processes for scrutiny by dardized work cells; visual these evaluators. Team Hill wishes them good management; and appropriate quality, cost and delivery metrics," Dr. Keller said. "An operaluck but we know they have prepared very well tional 'takt time1 (the pace of production needed for this unique opportunity," General Sullivan to meet customer demand) ensures that work is said. He added, "I know that the continuous process completed at precisely the right time." improvement journey is never-ending and we are After totally re-engineering the F-16 produccommitted to continually raising the bar in pur- tion processes to create a one-piece flow, the 573 suitof excellence. We are proud of the role set by AMXS team, along with General Sullivan, and the 573rd Aircraft Maintenance Squadron and former 309th Maintenance Wing commander, are encouraged that the Shingo examiners will Brig. Gen. Robert McMahon, initiated the CCIP also see first hand the outstanding work of this cellular flow process on June 1,2004. organization." "Expansion and refinement of our cellular flow process continues today. The two-year effort The Road to Shingo and subsequent results have generated a whirlIndustry leaders opened the competition to wind of interest and has made the F-16 depot public sector organizations last year. Before operations a must-see venue for visiting dignitar2005, the Shingo awards were limited to private- ies and associated customers," General Sullivan sector companies. said. When the awards were handed out last year, Cellular concept successful the Shingo Prize evaluators recognized Air Force Materiel Command's three air logistics The cellular concept is beneficial in several adcenters for their practical implementation of ditional areas: customer satisfaction has steadily Lean Transformation practices designed to creincreased, on-time delivery rates have reached ate value, eliminate waste and allow an organiza- the 100 percent pinnacle, the relationship betion to adapt quickly to change. tween the F-16 Aircraft Maintenance Squadron Two Ogden ALC organizations received silver and the F-16 Flight Test pilot community has awards: the F-16 Common Configuration Imple- been enhanced as problems and production-rementation Program, or CCIP, and the Commodi- lated issues are solved together. ties Branch Pylon Shop. "The operational units have complimented the The CCIP production line is an F-16 Fightentire F-16 production team's efforts and results, ing Falcon aircraft modification shop, part of with visits by pilots who successfully deployed the center's 309th Maintenance Wing. Its Lean the modification into a wartime environment," program focuses on structural and electrical imsaid Col. Art Cameron, 309th Maintenance Wing provements to extend the aircraft's service-life. commander. "They expressed their sincere apThe CCIP, which created the Air Force's first preciation for the quality product and expanded organic cellular flow line in 2004, has seen a 30 capability provided." percent reduction in flow days and an 80 percent He added, "Fellow partners in the aviation increase in defect-free aircraft. industry, from whom ideas and concepts were The F-16 Pylon Shop services the warfighter extracted and later refined and adapted to suit by maintaining, overhauling and repairing our own unique process, have visited our celwing-mounted fuel and weapons pylons on the lular flow lines to observe and understand our service's fighter and attack/bomber aircraft. successful endeavor. As a result, dialogue is now Its Lean processes reduced cycle time from 145 focused on how we can make each other better days to fewer than 18 days, enabling the shop to versus outdoing the other." 'BYMARILUTRAINOR [ Ogden ALC Public Affairs Office Shingo Prize Safety team assesses Hill AFB next week BYJV1ARIIJJTRALN0R The Defense Safety Oversight Council selected VPP for use within the Department of Workers in Hill industrialareas will be interviewed June Defense after data showed a 12-16 as part of Hill's efforts to reduction in mishap rates and participate in the Occupation- worker compensation costs in al Safety and Health Adminis- civilian and federal organizatration's Voluntary Protection tions that comply with VPP. Program. More than 1,000 injuries a VPP is a concept that proyear occur on military installations. motes worksite safety and "OSHA contracted with health. The VPP-oriented CTC to conduct visits to nine look provides incentives to Air Force Bases, four of which make workplace safety and are in Air Force Materiel Cornhealth changes that allow man," he said. "The contracmore employee involvement in identifying ways to improve tor will assess existing health their own safety. and safety measures. CTC "The ability of the employee representatives will compare to identify hazards in their those measures with preown workplace and get leader- established VPP health and ship commitment to address safety requirements and identhose hazards is the key comtify areas for improvement." ponent of the VPP program," To prepare for the assesssaid Lt. Col. Rick Palo, chief of ment, Hill safety and health the Ogden Air Logistics Censtaff conducted an initial self ter Safety Office. analysis to identify gaps in Colonel Palo said his office, VPP program requirements. as well as many other base CTC representatives made organizations, have prepared their first visit to Hill mid-May for this visit and they encourand talked with the base's seage all workers to welcome nior leadership. They return and assist the Concurrent next week for the assessment Technologies Corp. staff in phase. conducting the assessment. The team of approximately He said experts agree that 10 people will visit as much employee involvement is the of the base as possible to get ingredient required to take a picture of the current state a good safety and health proof the safety and health program from being compliance gram at Hill. During their oriented to one which is more visits, they will conduct inforproactive and wellness-orimal interviews with employented and in engrained in the ees in the work areas. There entire workplace culture. will also be an opportunity for "This program is designed approximately 60 volunteers to recognize organizations to participate in more formal that have exemplary safety interviews. and health programs," Colo"VPP is not a new or adnel Palo said. "VPP requireditional program, just a difments go above and beyond ferent measuring stick and the minimum OSHA requirepossibly ways of looking at ments." our current system," Colonel Ogden ALC Public Affairs What does a lucky dog and a biplane ^ have in common? ' L L "8 0 L sunr 'Moqs JJV aseg aojo #e You Still Sufferi i5TX yT.r _, SPINAL : . . ^ ,_ DECOMPRESSION :^.. .„..., ,—•>_ THERAPY ™ |ryi3ij suffer from low back or neck upaiiu-you owe it to yourself to try TX Spjnal-Decomprevsion Therapy an advanced; traciion based procedure. Our office specializes in this remarkabie,"effective and affordable treatment plairthat can relieve the pain associated with bulging, hemiatcd and deoenerjtlvc discs. Many of our patients report Ilie elimination of thai pain radiating down your leg or through your shoulders and anus. Don't forget to ask ahout our free Consultation and demonstration of these treatments. 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He added, "The Voluntary Protection Program is not a quick-fix. There will be some additional activity to initially get everything to a VPP level, and then it will become an ongoing effort after that. We look forward to working closely with the assessment team and receiving any suggestions they can provide to us." At the end of their visit, the assessment team will present the base with an analysis indicating where the current safety and health program meets or exceeds VPP criteria and where there is room for improvement. Approval into VPP is OSHA's official recognition of the outstanding efforts of employers and employees who have achieved exemplary occupational safety and health. OSHA approves qualified sites to one of three programs: Star (the DOD target is it signifies an exemplary health and safety program); Merit; and Star Demonstration (recognition for worksites that address unique safety and health issues). 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