Managing Lean Manufacturing in Oilfield Equipment Industry
Case Study
Research Problem
Operational objectives are set by top management and Lean Manufacturing is defined as a method of obtaining those objectives.
Operational management is giving a set of lean principles but no way of establishing how to apply them or implement them.
Operational management is often left with the task of defining the objectives of deploying lean principles.
Materials Handling is often one of the key sources of waste in many companies.
Research Objectives
The objectives of this study are:
To develop a methodology that can be used to assist in determining management objectives of lean manufacturing.
To show how this methodology can be used to assist in eliminating waste in material handling processes.
Case study will be limited to a single cell
Research Approach Review literature on lean manufacturing, its implementation and
material handling.
Overview of lean manufacturing and management objectives
Development of the Methodology
Case Study: Hughes Christensen
Conclusion and Direction for Future Research
Methodology
Management Input Lean Assessment Development of Lean Strategy Definition of Lean Objectives Selection of Lean Tools Solution Implementation
Case Study
Hughes Christensen Oil Services – Leading Drill
Bit Manufacturer Over 30% of Current
Market Share – Market Leader
Lean Manufacturing Current Implementation Deployment in ‘Diamond
Products’ Lafayette Manufacturing Facility
Case Study
Lean Manufacturing
Lean Manufacturing Mandated
Lean Tool Kit Provided
Addressing Material Handling in Diamond Products Remains an Issue
Management Objectives of Lean Manufacturing in Regards to Materials Handling Not Defined by Top Management
Research Process
Determine Management Objectives
Review layout / material flow
Select areas of Opportunity
Determine area with impact to management
objectives
Determine lean manufacturing
methods to implement
Survey / Interview
Management
Value Stream Mapping
Lean Assessment
Application of KPI’s
Application of Lean Tool Kit
Weigh Management Objectives
against Areas of Opportunity
Safety
Quality
Output
Customer Service
Management Objectives of Lean Manufacturing Defined
Implementing Management Objectives of
Lean Manufacturing
Research Process
Use Lean Tools to Develop a
Solution
Implement Solution
Standardize Solution / Report
on Results
Assemble Applicable
Metrics
Monitor Metrics
Sustain Lean Thinking
Continuous Improvement Loop to Develop a Holistic Solution
Determining Management Objectives of
Lean Manufacturing
Case Study
Hughes Christensen
Area of Opportunity Crown Machining Cell – Thread Connection for API
Connection Shank Machined and Shank Connected.
Problem Area – Material Handling of Connection Stock.
Performance Evaluation
Performance Measures
KPI Values Linked to Objectives of both Lean Manufacturing and Operational Goals.
Dependent upon needs and goals by Management (e.g. Incident Report, Productivity, Through Put, etc…)
Business unit and operational group goals
Cell Layout
Material handling value stream map – crown machine cell
Value stream map data – current state map
Lean manufacturing tools
Proposed Staging Device
Layout after lean implementation
Future state value stream map – crown machine cell
Comparison of current state and future state maps
Conclusion
Material Handling Layout and Flowchart Methodology
VSM – Current State
Performance Measures- Time; #Activities
Lean Tools
VSM – Future State %Savings