Lean Production
Lean production is an approach to manufacturing that strives to eliminate all kinds of waste (time, money, materials, etc.) while creating a culture within the plant of continuous improvement. Lean processes have long been used in other industries, notably automotive, to improve quality while reducing the overall cost of production; however, they are relatively new to the factory built housing industry.
Nine manufactured and modular home production plants were trained and coached in the implementation of lean production methods to their manufacturing facilities. Representatives from each plant attended a week-long training workshop on lean production conducted by SBRA (formerly known as MHRA). Following the workshop, researchers from SBRA helped plant employees analyze their production process using a lean production tool known as value stream mapping. Value stream mapping helped the plants identify waste and target specific portions of the production process for intensive improvement activities known as rapid process improvement (RPI) events.
Under the Lean Program, SBRA’s goal is to be the leading educator and catalyst for maximizing value and minimizing waste in factory homebuilding. To accomplish this goal, SBRA is developing and advancing lean principles, tools, and techniques designed to enable positive change. SBRA will facilitate the development and implementation of lean building methods throughout the entire factory home building process and related operations.
Getting Involved
Lean In Action
Factory Building Symposium on Lean Production
Presentations (must be viewed as a slide show)
Wall Production and Changeover Time - Hi-Tech Housing
Clutter to Cash - Palm Harbor Homes (Abemarle, NC)
Level the Load - Four Seasons Housing, Inc.
Management Commitment - Southern Energy Homes
Creating a Lean Infrastructure - Palm Harbor Homes (Plant City,FL)
Building from Small to Large - Clayton Homes
Building a Lean Culture - R-Anell Homes
Leveraging Lean - Chelsea Modular Homes
Empowering the Lean Team - Cavalier Homes, Inc.
SBRA Publications
Getting Lean: Assessing the Benefits of Lean Production in Factory Built Housing
Applying Lean Home Building Practices Beyond the Plant
Lean production, developed by Toyota, aims to cut waste in manufacturing and operations, emphasizing continuous improvement. Applied to manufactured homes, this project with Titan Homes in Sangerfield, NY, used lean techniques in sales and installation processes. This project report notes challenges in implementation and suggests strategies for improvement across the industry.
TECHNOLOGIES Column from Modern Homes Magazine - July/Aug 2006
TECHNOLOGIES Column from Modern Homes Magazine - Nov/Dec 2006
TECHNOLOGIES Column from Modern Homes Magazine - Jan/Feb 2007
Interview on Lean Production with Dr. Michael Mullens and Dewey Warden
Other Resources
R-Anell Gets Lean (Building Systems)
From 0 to 60 to World Domination (The New York Times Magazine)
Lean & Loving It (Building Systems Magazine)
