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Military airframe acquisition costs : the effects of lean manufacturing

Author: Cynthia R Cook; John C Graser; United States. Air Force.; Project Air Force (U.S.)
Publisher: Santa Monica, CA : Rand, 2001.
Series: MR/Rand Corporation, MR-1325-AF
Edition/Format:   Print book : EnglishView all editions and formats
Summary:
During the past couple of decades, many segments of U.S. industry have benefited from introducing new manufacturing techniques that save money by increasing efficiency and reducing overhead. Would U.S. military aircraft manufacturing benefit from these techniques as well? This report examines the package of new tools and techniques known as lean production to see if it would enable aircraft manufacturers to produce  Read more...
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Details

Document Type: Book
All Authors / Contributors: Cynthia R Cook; John C Graser; United States. Air Force.; Project Air Force (U.S.)
ISBN: 083303023X 9780833030238
OCLC Number: 46969863
Notes: "Project AIR FORCE."
"Prepared for the United States Air Force."
Description: xxii, 155 pages : illustrations ; 23 cm
Contents: Lean Manufaturing and Methods of Study --
The Lean Manufacturing System --
The Search for Productivity Improvements and the Genesis of Lean Manufacturing --
Overview of the Lean Manufacturing System --
Complexities and Challenges --
Lean Implementation in the Military Aircraft Industry --
Data and Methods --
Reporting Results: Accounting for Savings from Lean Processes in Defense Manufacturing --
The CCDR System --
Incorporating Lean Into Cost Estimates Using CCDR Categories --
Engineering --
Design Engineering --
IPPD and IPTs --
Cost Effects of IPTs --
Computer-Aided Design Technology --
Other Lean Enablers--Design Philosophies That Reduce Manufacturing Costs --
Unitization/Part Count Reduction --
Part Standardization --
Summary Results on Implementation of Lean Design and Development --
Tooling --
Tooling in the CCDR --
Advances in Tooling --
Self-Locating Parts --
Flexible Tooling --
Other New Tooling Technologies --
Summary Discussion of Lean Tooling --
Manufacturing --
Lean Manufacturing in the Factory --
Pull Production --
Cellular Production and Single-Piece Manufacturing Flow --
Takt Time --
Visual Control --
Housekeeping --
Location of Tools/Shadowboxes --
Shadowbox Kitting --
Manufacturing Best Practices That Enable Lean Production --
Summary Results on Implementation of Lean Manufacturing --
Specific Examples of Savings From Lean Implementation --
Lean Transformation at Brownfield Plants --
Summary of Typical Savings --
Quality Control --
First-Time Quality: A Keystone of Lean.
Series Title: MR/Rand Corporation, MR-1325-AF
Responsibility: Cynthia R. Cook, John C. Graser.

Abstract:

During the past couple of decades, many segments of U.S. industry have benefited from introducing new manufacturing techniques that save money by increasing efficiency and reducing overhead. Would U.S. military aircraft manufacturing benefit from these techniques as well? This report examines the package of new tools and techniques known as lean production to see if it would enable aircraft manufacturers to produce new weapon systems at costs below those predicted by historical cost estimating models. The authors give a broad overview of what lean is and what it can and cannot accomplish in cutting manufacturing costs. They also detail results of industry efforts in this regard, including specific examples and averages of claimed cost savings. The authors conclude by identifying areas where companies need to push harder in lean implementation and what the Defense Department can do to encourage this.

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