Home | Workforce Development | Grants Development and Management | MEP Affiliate Sites | SeaPort-e | Client List | Press Room | Success Stories | Contact Us
Time Wise® Success Stories
Time Wise Management Systems and Arizona MEP Assists Boeing Supplier to Improve Process and Product Output
PHOENIX, AZ - The employees at Ducommun Technologies are accustomed to big projects. The company, which serves the defense, aerospace, and aviation markets, builds mechanical and electro-mechanical enclosures, assemblies, and complex wire harnesses.
Through Raytheon, Ducommun Technologies is also a supplier to Boeing, the world's leading aerospace company and the largest manufacturer of commercial jetliners and military aircraft combined. Recently, Boeing contracted with Time Wise Management Systems (TWMS) and the Arizona Manufacturing Extension Partnership (MEP) to pilot a program for a small number of key suppliers, including Ducommun Technologies, to partake in a supplier integration process improvement program. This program included a Time Wise Value Stream Management System mapping session to show each factory’s product and process flow. This helps a company determine a more efficient layout. Each company then performed Kaizen events, short bursts of activity to make small improvements with a goal of making large gains in efficiency and productivity.
"Our goals, as part of this program, were to focus on one essential Boeing project, the APG-79 Radar Rack and increase the number of units produced per month while cutting down assembly hours at the same time," said Mike Williams from Ducommun Technologies’ Phoenix facility.
To start, John Dubois of the TWMS trained 23 key employees on the Time Wise Principles of Lean Manufacturing. Lean Manufacturing is a technique that uses basic but effective concepts to identify and help reduce waste and increase productivity.
"We began with a Kaizen event that helped rework the cell. It went from a general assembly area to a five station cell where parts flow from sub-assembly, to assembly stations, to final assembly," said Dubois. "We then put material in bins and made shadow-boards for station-specific tools. Each station now has a computer for access to standard work instructions, so everyone will understand each step. Now a lot of time is being saved with a few simple changes, and the employees are able to work more efficiently."
The company is now able to produce six units of APG-79 Radar Rack per month instead of three. The lead time through assembly was reduced from 50+ days to an average of 25 days, and their hours per assembly went from almost 147 hours to just under 96 hours.
"The Time Wise Management Systems and Arizona MEP showed us how to be more organized, and improve all aspects of our production line," added Williams. "We plan on duplicating these Lean activities to other areas of the shop, which will also result in improvements to Boeing and other manufacturers we supply." (For more information contact Preston Shoaf, 602-305-4939.)