Naval Air Depot Jacksonville gets LEAN
By Susan Brink, NADEP Public Affairs Specialist

With ISO 9001:2000 and AS9100 certification under its belt, the Naval Air Depot Jacksonville (NAVAIR Depot Jax) continues to look at ways to improve. As stated by Cmdr. Ron Bethmann, Production Support Officer, “The best improvements are not the ones we get from outside sources, but the ones that our employees create. It just doesn’t happen because we want it to, we must provide employees the right tools to make their ideas reality.” NAVAIR Depot Jax has determined that the next step to be taken to become a world-class organization is the empowerment methodology known in the industry as LEAN Operations.

So what is LEAN, and why use that tool in the depot environment? LEAN is simply a methodology that was initially developed by the Japanese to manufacture automobiles, referred to as the Toyota Production System. The methodology has evolved into a very dynamic tool set that is applicable to all businesses and disciplines. Its primary focus starts with the identification and elimination of waste. Waste, in this instance, refers to any activity in a process that does not add value to the generation of a quality product. Some examples include the time associated with waiting for parts or paperwork, searching for parts, and walking around the plant to retrieve tools, parts, or work instructions. LEAN also transforms production processes from an inefficient push system to a more efficient and less costly flow and pull system.

There are other businesses in the industry that utilize the LEAN methodology and have seen success. NAVAIR Depot Jax has partnered with General Electric Aircraft Engines to see what has worked for them and identify processes throughout the Depot to review. Bethmann described, “The war on terror has significantly increased the demand for the parts we produce for the Warfighter. Because of that, we must accelerate our continuous improvement efforts to increase our throughput, decrease our turn around times (TAT), and do so with our existing resources. Lean is about working smarter, not harder.”

During the week of July 8, 2002, the Depot took on its first LEAN project in the F404 HPT Rotor Repair Shop. After developing four teams, they spent the week reviewing processes and looking for ways to make improvements. The Assembly Team determined that they had an average queue time of 24 days and found it really only takes 15.6 hours, an improvement of over 98 percent. The Disassembly Team had an average TAT of 15.5 days and ultimately brought that down to a half-day, an improvement of over 96 percent. The Induction/Shipping Team determined that it had an average TAT of 19.25 days and brought it down to 1.4 days, an improvement of over 93 percent. And, the Material Allocation Team determined historically that its material allocation contributes an average of 90 days queue time and set a goal to reduce it by at least 30 percent. These are just some of the examples of improvements that were made to the F404 HPT Rotor Repair Shop by utilizing the new LEAN methodology.

NAVAIR Depot Jax employees have worked as a team identifying ways to improve efficiency in the F404 HPT Rotor Repair Shop. “Giving employees the right tools makes their ideas reality,” says Bethmann. ”This is only the beginning. As we learn more about applying LEAN principles, these continuous improvement efforts will migrate throughout the plant in the months and years to come,” says Bethmann.

Photo Captions:

Photo Reconfigure storage stand by Victor Pitts, Public Affairs Specialist: From left: Employees Larry Gibson, mechanic; Lanora Williams, mechanic; Chris McAdams, process engineer; redesign tool storage stand.

Photo LEAN Overview by Amy Cheshire, Public Affairs Specialist: Bill Harding from GE LEAN Manufacturing discusses accomplishments made by F404 HPT Rotor Repair Team in the first LEAN event.

Photo Ribbon Cutting by Amy Cheshire, Public Affairs Specialist: Holding scissors: Dora Ramon, buyer planner; Ron Chipman, mechanic work leader; Johnna McKinnon, mechanic; and Linda Brinkman, hub scheduler cut the ribbon at the dedication of the redesigned work area.

Photo Work in progress by Victor Pitts, Public Affairs Specialist: Jerry Majoca, GE Six Sigma Black Belt discusses LEAN process with members of the Depot F404 HPT Rotor Repair Team.

Photo Worker in shop by Victor Pitts, Public Affairs Specialist: Ken Gross, mechanic from the F404 HPT Rotor Repair Shop.

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