Boeing 2005 Annual Report Download - page 15

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2006 Initiative Spotlight: Lean+
Our Lean+ initiative will
accelerate and extend
the application of Lean
principles further into our
factories and beyond to
our front and back office
operations.
Boeing people have success-
fully applied Lean processes
to improve productivity in sev-
eral major product lines. For
example, on the 737 moving
assembly line, we cut final
assembly time by 50 percent
and are now adapting those
successes to the 777 assem-
bly line. Lessons learned from
737 and 777 assembly are
being leveraged for 787
assembly, with the goal of
achieving a three-day flow.
In partnership with suppliers,
the C-17 program used Lean
principles to help reduce the
cost to the U.S. Air Force for
C-17s delivered in 2005 by
more than 20 percent from the
previous contract, while
improving margins and adding
significantly more capability.
These improvements and oth-
ers owe much to the ingenuity
of Boeing employees, who
apply fresh thinking to stan-
dard Lean principles. For
example, two Boeing employ-
ees modified a hay elevator for
seat installation, reducing
installation time by two-thirds
and personnel needed to lift
the seats from the factory floor
into the airplane by one-third.
Colleagues on assembly lines
in other facilities adapted their
innovative approach, creating
additional savings.
Lean+ will take our pro-
ductivity improvements
to the next level.
We’ve done Lean well, but to
be more productive and sup-
port future growth, we need to
do it better and across the
entire enterprise. That’s what
the “+” in Lean+ is about —
expanding Lean principles fur-
ther in our factories and
beyond into our office environ-
ments and to our suppliers’
and customers’ operations.
We’ve asked Alan Mulally,
chief executive officer of
group flow time by 35 percent,
and increasing weekly volume
from 50 pieces to 120 without
adding resources. As a result,
the team moved work more
quickly to our enterprise part-
ners and was able take on
work supporting development
of the 787.
Lean+ is all about employees
taking a look at what they do
every day and doing it more
efficiently by relentlessly elimi-
nating waste, shortening lead
and cycle times, reducing
transactions and improving
quality while adding value —
even in the smallest opera-
tions. Doing all these things will
allow us to maintain a compet-
itive advantage over our com-
petitors, continuously improve
productivity and position our
business for long-term growth.
running leaner
Boeing Commercial Airplanes,
to be the corporate sponsor
of Lean+, demonstrating our
strong commitment to this
initiative.
We can leverage the experi-
ence of teams that are already
implementing Lean in an office
environment. Our 737 Airframe
Engineering Lean work team
applied Lean principles to
streamline their work pro-
cesses, reducing time spent
correcting errors by more than
50 percent, decreasing work
13