Word: reds
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...employees are part of the equation. At Red River, for example, broken vehicle hub gears used to be carted off to an area where several mechanics worked on them at three different tables. Workers came up with the idea of building one long table with an oval track on it that could slide the parts smoothly and quickly to each of the mechanics, whose tools were within easy reach. Evans is also taking some employees on site visits to efficient private-sector plants, like the British company BAE Systems' facility in York, Pa., where Bradley Fighting Vehicles are built. John...
...many cases, the Army is turning to the private sector for help. The service lets 200,000 contracts each year, and some companies, like Honeywell, Northrop Grumman and BAE Systems, work hand in hand with Army staff on the factory floor. At Red River, for example, BAE spent thousands of dollars for new equipment and physical improvements to the plant. The company has also posted an on-site representative at Red River to oversee repair work on transmissions for BAE's Bradley. Working together, the BAE--Red River team increased output from 1.5 to 4 units per shift. In many...
Even advocates of the Army effort recognize the challenge. Employees at all levels must adopt a new work ethic, learn new systems and often work harder, with no immediate rewards. At Red River, Evans asked his 300 supervisors to volunteer for intensive Lean Six Sigma training but felt that not enough embraced it, so last month he required attendance. "Ninety-nine percent of my folks are onboard, but a few have said they will retire rather than adopt the concept of Lean Six Sigma," Evans says...
...Evans, the Army's efforts are much more than a business-school exercise. "This is not only an economic transformation but a huge cultural change," he says. In the corner of every office at Red River, and on all the shop floors, stands a black cutout figure of a soldier with a helmet and rifle at the ready as a constant reminder of who the customer is and that the smallest errors can have the most serious consequences on the battlefield. A sign affixed to the front of the silhouette soldier says, WE BUILD IT AS IF OUR LIVES DEPEND...
...RED SHOES...