Lean Manufacturing Independent Work Cells

Setpoint Systems will automate and streamline the back-end manufacturing process for Lake City Army Ammunition Plant operated by Alliant Techsystems. The site will leverage lean automated solutions to drive productivity and quality. This is a plant that has manufactured ammunition since World War Two and is ready to be upgraded to new processes and work-cell layouts. ...

... "Setpoint’s solution for LCAAP involves identical but independent work-cells. Each work-cell can manufacture all the required products, but the work-cells are smaller, easier and faster to maintain than current processes. The new system will increase production uptime by 90 percent. The lean work-cells reduce part handling and part transportation, which reduces the risk of damage and errors to the ammunition. Greater automation saves ATK labor costs and improves worker safety. Most importantly, Setpoint’s solution incorporates in-process inspection and error-proofing to improve the quality of the overall product. " ...

Via Setpoint: Lean Manufacturing at Army Ammunition Plant

Tour of Lake City ammo plant via Army Website: "The command sergeants major were very impressed with the level of professionalism and detail that goes into producing munitions. "

ATK Lake City Army Ammunition Plant via Reuters: "The plant is the nation's primary production source for small-caliber rifle ammunition. At this plant, ATK produces a mix of cartridges. Currently, 1.4 billion cartridges are produced per year ... "

Army Plant Lean Manufacturing Modernization

Setpoint Systems will modernize the Army's back-office manufacturing process for 7.62mm ammunition cases at the Lake City Army Ammunition Plant. Setpoint will integrate lean manufacturing principles to achieve operational efficiency, increased output, and enhanced product quality. ...

... "The U.S. government and ATK (the private company who manages the plant) realized that the time had come to modernize this manufacturing process. Setpoint gave ATK the perfect modernization solution through lean manufacturing. Lean manufacturing is based on the Toyota Production System (TPS) methodology, which breaks manufacturing processes down into multiple, compact workcells rather than using the enormous manufacturing lines common in the 20th century. " ...

Via Setpoint Systems: Army Ammunition Plant

Cycle Time Reduction using Lean Manufacturing on the Line

Boeing implements lean practices into its manufacturing processes, called the pulse line, for satellite production. ...

... "New work cells, new tooling, standard work-planning packages and lean manufacturing processes will reduce the total build time per satellite and increase the number of vehicles moving through the line at one time, according to the company. " ...

Via Inside GNSS: Boeing Pulse Line

Lean Quick Changeover

The lean workcell requires the ability to accomodate quick changeovers. ...

... "In fact, the ability to change the process and go from good part to good part as quickly as possible is a must. The faster the changeover, the less production time is lost. " ...

Via Electronics Supply & Manufacturing: Lean Principles

Lean Maintenance Supports Aerospace MRO

Lean manufacturing techniques are pervading the maintenance overhaul and repair processes of aerospace companies. Overhaul cycle time is decreasing as a results. ...

... "Pulsed moving lines, point-of-use kitting, pull systems, self-directed work cells - all the buzzwords of lean manufacturing are now being heard across commercial and military maintenance and modification. " ...

Via Flight International: Lean in Maintenance MRO Processes