Raytheon Integrated Air Defense Center, Andover, Mass.
Employees: 4,223, union
Total Square Footage: 1.7 million
Primary Product/Market: Patriot Missile Defense Systems
Start-Up Date: 1970
Achievements: 6% productivity improvements since 2007; reduced manufacturing floor space by 45,000 square feet in 2009; 20% reduction in standard order- to- delivery lead time reduction for missiles since 2007
It's only 11 a.m., but the roar of a crowd emanating from Raytheon Integrated Air Defense Center's Andover, Mass., cafeteria is unmistakable. It sounds more like overtime of an NBA game than late-morning in a manufacturing facility.
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| A worker at Raytheon Integrated Air Defense Centers Andover, Mass., facility performs a precision hand solder to a circuit in the circuit card assembly department. The department has achieved a 50% reduction in changeover time over the past three years. |
Upon closer inspection, all the commotion derives from a pep session for a team of two dozen operators that has pitched ideas on how to improve its department workflow. The team competes against 135 other groups at Raytheon's Andover facility. And make no mistake, the competition here is fierce.
That emotional stake is the very essence of how Raytheon Andover was able to not just overcome the potential shuttering of its doors a decade ago, but ultimately rebound to become one of the most advanced production centers for defense systems in the U.S.
Since 2007, Raytheon Andover has seen productivity improvements of 6%. One of its largest programs, the Patriot Missile, has had 100% on-time delivery over the past two years and registered a 0% customer reject rate since 2005. In 2009 alone, Raytheon's continuous-improvement campaign resulted in the reduction of manufacturing floor space requirements by 45,000 square feet.
Seven years into its continuous improvement journey, Raytheon has refined its processes and engaged its workforce. Now the leadership team finds itself in a position many advanced CI companies do, which is to forge the next evolution of lean.
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| See the other winners of IW's 2010 Best Plants award and find out how they made the top ten. |
"When we started this journey, I had no idea how long a journey it was going to be," says Michael Shaughnessy, senior director of operations at Raytheon's Andover facility. "There's still so much opportunity to be gained. Today, I have more to do in the next six months in improving how we run this operation than I did three or four years ago. That's unexpected."
Shaughnessy says Raytheon has cultivated relationships throughout its supply chain to focus on continuous improvement. The company has begun discussing with suppliers new ways to reduce cost, make products more affordable and improve quality.
Raytheon has recently undertaken several intriguing long-term CI projects. Two years ago, for instance, it instituted an interdependent approach to supplier management, creating communications elements within project lifecycle to spur faster flow and responsiveness to the customer from engineering, operations, supply chain and quality.
It has also begun a collaborative scheduling project to align the disconnects between the MRP (manufacturing) and ADT (engineering) systems, which schedule from opposite points of view -- manufacturing from the back end and engineering from the front end. Raytheon instituted a virtual business system to track all engineering, supply chain and operations progress when a program is brought into production, ensuring visibility and management of detailed milestones all the way to the supplier level.
But the real opportunity, Shaughnessy says, is to implement continuous improvement at the beginning of the product lifecycle, not during production. To do that, he says, requires "shifting resources, be it operations, engineering or supply chain, to the front-end of the process versus the latter end where we are today. That's gradually happening each year."
