1	IME 663 Lean Enterprise Lab Experience Spring 2007
2	IME 663 – Lean Enterprise Lab Experience Purpose. Apply lean manufacturing concepts to a simulated manufacturing process. Challenge. Manufacture 108 paper airplanes in a half-hour period. Metrics. Total profit, number of airplanes produced, man-minutes per airplane.
3	About the Airplanes Three models “A” model (top) Demand = 60 per session “B” model (middle) Demand = 30 “C” model (bottom) Demand = 18 Four units per sheet of paper possible
4	Manufacturing Process Trace outline and fold marks on CNC Cut outlines Fold Tape center seam Deliver airplane to customer
5	Initial Lab Push production control Lots of inventory/ WIP Poor layout Production bottleneck at trace (on CNC) Inefficient program Slow changeover 24 airplanes in 45-minute session Demand = 108 airplanes per 30-minute session
6	The Teams Diversity Six graduate students Innovators Five graduate students Two undergraduate students Lean Machine Six graduate students Teams assigned at random
7	Best Practices Shorten changeover time Limit internal (machine-idle) tasks Externalize changeover tasks Improve productivity of bottleneck operation Carbon paper 4-pen fixture Move operations off bottleneck
8	Best Practices (cont’d) Arrange factory for flow Production kanbans to prevent overproduction Label work areas Ensures all tasks performed Continuous improvement
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18	IME 663 Initial Lab Results Round 1 24 airplanes in 45-minute period 15.6 man-minutes per airplane $416 loss Round 2 40 airplanes in 30-minute period 6.0 man-minutes per airplane $9 loss Round 3 26 airplanes in 30-minute period 8.6 man-minutes per airplane $38 profit
19	IME 663 Final Lab Results Diversity 203 airplanes in 3 rounds (108 in final round) 2.2 man-minutes per airplane $112 profit Innovators 207 airplanes in 3 rounds (101 in final round) 2.1 man-minutes per airplane $159 profit* Lean Machine 211 airplanes* in 2 rounds (108 in final round) 1.2 man-minutes per airplane* $142 profit * indicates category leader