By Jamey Giddens
The Business Journal of Corpus Christi, September 20, 2007
Corpus Christi Army Depot is the proud recipient of the Shingo Public Sector Bronze Medallion. The Shingo Prize for Excellence in Manufacturing is named for Japanese industrial engineer Shigeo Shingo, according to the award’s official Web site. Business Week magazine has referred to Shingo as the “Nobel Prize of Manufacturing.” The award is presented by Utah State University. Public Sector Prizes are awarded by Shingo to organizations that “promote world-class manufacturing strategies and practices to achieve world-class results in the public sector/government owned facilities.” CCAD received the honor based on the stellar accomplishments made on its H-60 JDLM Pavehawk Program.
“This is truly an indication of dedication, commitment and a first class organization,” said newly-minted CCAD Commander COL Joe Dunaway. “Our Lean Team and the entire CCAD workforce did a great job. I am humbled to have joined such a great group. Now that the sound barrier has been penetrated, the sky is the limit.”
CCAD submitted the H-60 JDLM Pavehawk Program due to the stellar success the Depot has had on the line in regards to shaving Cost and Turnaround Time (TAT) on the H-60 JDLM Pavehawk line, while drastically improving quality. These improvements could not have been accomplished without a commitment to Lean Six Sigma, said Lean Chief Frances Rosarius.
Thanks in part to Lean Six Sigma, as well as other complimentary Depot initiatives such as Process Based Leadership (PBL) and a commitment to certification into the ISO family of standards (ISO 9001:2000, AS9100, AS9110) CCAD noted many significant improvements including:
- Turnaround Time (TAT) on the H-60 JDLM Program decreasing by 45 percent.
- Man hours per unit dropping 47 percent.
- Space utilization for the assembly process going down by approximately 10,500 square feet.
- Overhaul Cycle Time (OCT) on the T-700 engine line dropping from 272 days in 2001 to 78 days by 2006.
- UH-60 Recap being reduced TAT from 436 days in 2003 to 326 days in 2006.
Quality and Safety
- Corrective Action Requests dropping from 5. 7 in 2006 to 2.7 in 2007 per audit.
- OSHA Recordables being reduced by 41 percent from 2005-2006 on the H-60 JDLM line.
- First time tell cell yield increasing from 40 percent to 90 percent.
- For H-60 JDLM, reducing cost overruns by 73 percent.
- Increasing On-Time Delivery for the H-60 JDLM Pavehawk from 8 percent to 90 percent.
- Increasing output levels for the UH-60 Blackhawk Recap by 123 percent from 2004-2005.
Representatives from CCAD will accept the Depot’s Shingo Public Sector Medallion during an awards ceremony Oct. 11, 2007 at the Hyatt Regency-Crystal City in Arlington, VA.