Original Date: 09/14/1998
Revision Date: 01/18/2007
Information : Stinger Training Room and Agile Factory
Recently, Raytheon Missile Systems Company (RMSC) completed the innovative installation of a training process for the Stinger missile assembly operations. This process ensures that assembly and test personnel receive the latest training, and provides the company with a cadre of cross-trained individuals who can perform all of the operations for updating/building the subassemblies of the Stinger missile.
As RMSC incorporates newer versions of the Stinger missile into its operations, numerous obsolete and scrap subassemblies/parts are accumulated. Instead of discarding these items, the company uses them to build mockups of the missile’s assembly stations for training purposes. Each station also contains the necessary tools, test equipment, and process instructions for that operation. The Stinger Training Room simulates RMSC’s Agile Manufacturing area, and allows personnel to learn or practice new techniques and processes (e.g., assembly/disassembly, testing, troubleshooting) on actual hardware. In addition, employees are cross-trained in all functions of the Stinger’s assembly operations. With this training, RMSC assures that the desired results of Agile Manufacturing initiatives will be realized.
Besides the technical training room, RMSC’s Agile Manufacturing area also utilizes new line flow balance techniques; a self-contained supermarket for required materials; a flexible floor layout and adaptive infrastructure; lean tooling; workplace organization; and an effective shop floor control system. All employees in the factory are fully trained in the processes and theories of Agile Manufacturing. By implementing Agile Manufacturing methods and tying this focus to the technical training room, RMSC has realized significant savings in the Stinger missile assembly operations. These successes, after only 13 months of implementation, include:
Factory WIP reduced by 84% Pilot area WIP reduced by 87%
Inventory turns improved by 255%
Factory cycle time improved by 81%
Pilot area cycle time improved by 89%
Factory WIP to sales improved by 89%
Factory delinquencies improved by 69%
Pilot area delinquencies improved by 98%
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