lean labs: improving lab efficiency through workspace improvements

Engineering, Operations & TechnologyBR&T

BOEING is a trademark of Boeing Management Company.Copyright © 2013 Boeing. All rights reserved.

Lean Labs: Improving Lab Efficiency through

Workspace ImprovementsSWE 2013 National Conference

October 25, 2013

Michele ChaffeyThe Boeing Company

Engineering, Operations & Technology | BR&T

Copyright © 2013 Boeing. All rights reserved.

Materials & Manufacturing Technology

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What is Lean Labs?

Lean Set of tools and techniques used to manage a work environment in a

more safe and efficient wayLaboratory environment Eliminate wasted space time, and motion, and unnecessary supplies,

stock, and equipment Streamline workflow Improve safety and ergonomics

Boeing program developed in 2011 to help BR&T labs become more efficient Based upon Lean implementation in the Boeing Interiors Lab ~ 2008 Over 25 labs in BR&T have used the program

Lean Labs is not research, it’s improving the business side of research




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Simple, Team-Based Approach

Well-defined, short-term project to improve one existing process or workspace

Involve all the stakeholders from the beginning Input work and/or requirements Customers of output/results Work the process and utilize the space

Unified team - Input from everyone Educate staff on the Lean goals Increase buy-in for the improved process/workspace

Not management pushing a new set of requirements or methods onto staffIs whole team working together to improve processes




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Know Your Objectives First

Identify major issues Workflow Storage Equipment / tools (use, location) Tracking / prioritization of jobs

Set aside specific time to tackle each issue Designated shut-down time (e.g. 1 continuous week) Specific regular short spans of time (1-2 hours /day)

Increase efficiency by working smarterBe willing to spend some budget on organizational

equipmentMake the space work for the processes not vice versa

Improvements do not come by accident, they must be deliberate




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Benefits Experienced by All Stakeholders

Improved Utilization of space Improved Efficiency Improved MoraleAvoid costs due to Quality FindingsAvoid costs due to Safety and Ergonomic issues Improved Customer Satisfaction

Improvements will not last unless everyone benefits




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How Does it Work? What Does it Look Like?

Following are specific examples and lessons learned from Extreme Environments R&D labs workshop

What we do Perform research, development, and testing for Boeing organizations

Fabrication of test articles Labs have many years of inventory, equipment, and consolidated

workspace Our goals for Lean Lab Event Improve workflow through lab Excess unused/out-of-date tools, equipment, supplies, etc. Organize usable tools, supplies, materials

ADD MORE HERE

Labs may not be production areas, but they still need to deliver




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Don’t Let Tradition Dictate Your Space

Replace out-of-date or previous process set-ups, equipment, and storage with what works for current processes or projects

Before After

It has always been here, so we must need it

Other labs use it so we should keep it




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One Lab’s Treasure is Another Lab’s Trash

Just because it is a great piece of equipment, does not mean it is right for your application

Before

After




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Shelving, Wheels, and Label Makers – Oh My!

Clutter and precarious box stacking are physically dangerous Bad or no labeling system is fiscally dangerous

After

Off the shelf storage solutions - more cost effective

Before




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Organize Storage to Meet Your Needs

Before No organization of test specimens Tool boxes blocked Overhead cabinets inaccessible

After Wire racks configured for high

volume specimen retention Tools and supplies moved to more

accessible areas




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Invest in Storage Solutions

Supplies/equipment in plain sight remain more organizedMobile tool racks can be moved to point of use




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Before

Utilize Space Efficiently and Make it Flexible

Electronic storage requires less space than paper Moveable work tables make space reconfigurable Keep tools & equipment at point-of-use locations

After




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Let it Roll!

Furniture on wheels allows easy lab reconfiguration




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Utilize “Moonshine Shops” for Custom Needs




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Set up Space for Specific Projects where Possible

Active Flow Control LabAblator Mix room

Utilizing Lean to enable and facilitate more effective research




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Take it Away!

Lean Labs is a deliberate concentrated approach to increasing lab efficiency through workspace improvements

Must engage all staff involved with the lab including engineers, technicians, customers, and managers

Make the space work for the processes in the lab Customize storage solutions for specific needs

Many off the shelf solutions can be tailored to your requirements Clear out the clutter Make workspace reconfigurable (even specific process space) Keep tools/equipment at point-of-use

Post-event self-discipline is the hardest part Keep staff involved from the start Get buy-in to the philosophy with on-going management support




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Does it Work?

Before After

BR&T Lean Labs program has an average score of 4.2/5.0 from participants