Lean Six Sigma: Tobyhanna 5M540 Kitting Process

Abstract

The 5M540 Cost Center is responsible for kitting at the Tobyhanna Army Depot. Over the course of this project, the group used lean six sigma methodology to reduce schedule variance. Each phase in the DMAIC Process (Define, Measure, Analyze, Improve, Control) is made up of tools tailored to address the project's goals. With a team approach we identified root causes for missed schedules and delayed production orders. Our recommendation and final solution to address schedule variance was a process accountability mechanism to ensure communication, coordination, and accurate estimates that would be integrated into scheduling data. Along with this improvement we leveraged a variety of quick wins to improve process efficiency such as a reorganized floor layout, cleaned shop floor, and data entry techniques.