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1、KAMANDAYRON,Inc.BeginningtheLeanJourneyatKamanDayron:ACaseStudyinSupplierDevelopmentJimLobbanDirectorofSiteOperationsKamanDayronOrlando,FLBradCamplingProgramDevelopmentManagerTechSolveCincinnati,OHKAMANDAYRON,Inc.AboutKamanDayronDayronhasbeenadefensesuppliersince1968PurchasedbyKamanAerospacein2002Ma
2、tureProductionProgramsM54940MMGrenadeFuzeM549A140MMGrenadeFuzeM550EscapementforM91840MMPracticeProjectileM223GrenadeFuzeBLU-97SubmunitionFuzeforCEM&JSOWFMU-143FuzeforPenetratorBombsFMU-156JointAirtoSurfaceStandoffMissile(JASSM)FuzeStart-UpProgramsFMU-152JointProgrammableFuze(JPF)FMU-139FuzeDevelopme
3、ntProgramsAdvancedCrewServedWeapon(ACSWFuze)M549A1E1SelfDestructFuzeKAMANDAYRON,Inc.JointProgrammableFuzeFMU-152A/BandFZU-55A/BWorkswithmostmainstreamguidedandunguidedairtosurfacebombsintheAirForceandNavyinventoryCompatiblewithsamesystemsthatuseallvariationsoftheFMU-143andFMU-139ApplicationsDelayFuz
4、eforhardenedburiedtargetsSurfaceimpactforsurfacetargetsAltitudeburstwhenusedwithaproximitysensorforareatargetsAllowsaircrewstochangeFuzesettingsinflight(priortoweaponrelease)KAMANDAYRON,Inc.KAMANDAYRON,Inc.TheNeedforLeanatKamanDayronKamanDayronwasbeginningfourthattempttopassFirstArticleAcceptanceTes
5、ting(secondunderKaman)DirectAttackSPOrecognizedaneedforchangebeginningwithLeanManufacturingprinciplesandlookedtoAirForceManTechforassistanceAFManTechreliedonitsexperiencewiththeJDAMSMEIprogramPartnershipbetweenAFManTech,Boeing,andTechSolveFour-yearsupplierdevelopmentprojectamong8smallsuppliersandHon
6、eywellGoaltotransformsuppliersintoleanorganizationstomeetprice,qualityanddeliverygoalsAFManTechpartneredwithTechSolveatthebeginningofFAATIVtoworkwithKamanDayrontohelpbuildaLeanproductionsystemKAMANDAYRON,Inc.ProblemFirstArticleAcceptanceTest(FAAT)ThreeconsecutiveunsuccessfulattemptsWorkmanshipdefect
7、sledtomajorityofFAATfailuresCreateddelayinavailabilityoftheJPFfuzetoWarfighterKAMANDAYRON,Inc.TechnicalApproachIdentifiedworkinstructioninterpretationasamajorvariabilityamongassemblypersonnelEngineeringdocumentsheavyonwordsContainedafewblackandwhitetechnicaldrawingsDecidedtobuildworkinstructionswith
8、avisualrepresentationoftheassemblyWorkedwithengineersandoperatorstodevelopbestpracticesforassemblyDocumentedwithphotosanddetailedcaptionsforeachassemblystepKAMANDAYRON,Inc.StandardWorkExampleOldWayNewWayKAMANDAYRON,Inc.SuccessfulFAATIVYesStaticFire9YesSledTest5YesFlightTest36YesEnvironmental/Operabi
9、lity36MetAcceptanceCriteriaTestUnitsKAMANDAYRON,Inc.NextChallengeLowRateInitialProduction(LRIP)SuccessfulcompletionofFAAT=IncreaseddemandLRIPawardreleasedoninApril2004KamanDayronneededtomeetaggressiveproductionrampmilestonestosatisfydemandKAMANDAYRON,Inc.Baseline(1stQuarter2004)Developedacomprehensi
10、veVSMwithdetailedinformationabouteachsubassemblyDocumentedbaselinedataforcycletime,changeover,uptime,workingtime,scraprate,etc.BombInitiatorOp80MarkInitiatorBombInitiatorOp90SecureLanyardtoInitiatorBombInitiatorOp95InspectionOperatorCycleTimeMins2.96TaktMins57.72ProcessMins/ShiftMins570ProcessShifts
11、/DayShfts1RequiredDemandPcs0.00Yield(%)%100OperatorsStaff0.00OperatorCycleTimeMins0.5TaktMins57.72ProcessMins/ShiftMins570ProcessShifts/DayShfts1RequiredDemandPcs0.00Yield(%)%100OperatorsStaff0.00OperatorCycleTimeMins2.85TaktMins57.72ProcessMins/ShiftMins570ProcessShifts/DayShfts1RequiredDemandPcs0.
12、00Yield(%)%100OperatorsStaff0.00InitiatorPWBOpxxxSMTInitiatorPWBOpxxxSolderPasteInitiatorPWBOpxxxReflowInitiatorPWBOpxxxInspectionInitiatorPWBOpxxxCutfromPanelCoverAssyInitiatorOp20AssembleDowelPintoCoverCoverAssyInitiatorOp25InspectionCoverAssemblyOp20AssembleandSolderFlextoTurbineCoverAssemblyOp30
13、AssembleAirInlettoInitiatorCoverCoverAssemblyOp35InspectionInitiatorSubOp20AssemblePivotLink,TorsionLinkandSpringBaseInitiatorSubOp30AssembleLinkAssytoCoverAssyInitiatorSubOp35InspectionBombInitiatorOp15SlapperFunctionalTestBaseAssyOp35InspectionBaseAssyOp30InstallPWBandSolderBaseAssyOp20AssembleTra
14、nsducerBaseSubOp45InspectionBaseSubOp40InstallRetainingClipsandGasketsBaseSubOp30LeakTestBaseSubOp20InstallHeadersandWeldInitiatorHousingOp25InspectionInitiatorHousingOp20InstallHousingLocksBombInitiatorOp20InstallInitiatorSubintoHousingBombInitiatorOp25InspectionBombInitiatorOp30InstallBaseBombInit
15、iatorOp35InspectionBombInitiatorOp40aWeldBasetoHousingBombInitiatorOp40bWeldSealtoHousingBombInitiatorOp50LeakTestSealAssyOp25InspectionSealAssyOp20WeldInitiatorBackPostBombInitiatorOp55InspectionBombInitiatorOp60WeldScrewtoBaseBombInitiatorOp70LeakTestBombInitiatorOp75InspectionBombInitiatorLATOp80
16、MarkInitiatorBombInitiatorLATOp90SecureLanyardtoInitiatorBombInitiatorLATOp95InspectionLanyardOp45InspectionLanyardOp40CrimpWireRopetoLanyardTerminalsLanyardOp35InspectionLanyardOp30CutWireonFlashCutterLanyardOp25InspectionLanyardOp20AssembleTerminalsandShearingWiretoLanyardBodyFuzeSubOp100MarkFuzeHousingFuzeSubOp130ApplyLabelandWireWrapFuzeSubOp135InspectionOperatorCycleTimeMins2.34TaktMins57.72ProcessMins/ShiftMins570ProcessShifts/DayShfts1RequiredDemandPcs10.00Yield(%)%100OperatorsStaff0.04Ch
