1. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner Lean Lessons Learned at Tobyhanna Army Depot

2. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner “The Good, The Bad, and The ‘What The Heck Were We Thinking’” ✔ Desired Outcomes: ●Participants leave here with one or two ideas worth trying ●Participants leave here able to avoid mistakes we’ve already made. Lean Lessons Learned at Tobyhanna Army Depot

3. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Disclaimers: ●We are less than perfect ●We’ll address our warts -- this isn’t a marketing pitch ●I’m sure we could learn from each of you ●We’re getting better ●We’re building on foundation built by others Lean Lessons Learned at Tobyhanna Army Depot

4. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Directorate of Productivity Improvement and Innovation ●Established Oct 03 ●142 personnel ●Total Approach to Continuous Process Improvement ●Lean Six Sigma (3 divisions) ●Quality (2 divisions) ●Industrial Modernization Army Suggestio n Program Value Engineerin g Program ISO Certificatio n 6S Lean Six Sigma at Tobyhanna Army Depot

5. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Employee Participation ●FY06: 702 ●FY07 YTD: 482 ●FY07 Year End Projection: 738 ●Total Since Inception: 2,175 (64%) ✔ Lean Events ●FY06: 179 ●FY07 YTD: 124 ●FY07 Year End Projection: 199 ●Total Since Inception: 575 ✔ Savings / Avoidance ●FY06: $16.9M ●FY07 YTD: $14.0M ●FY07 Year End Projection: $18.6M ●Total Since Inception: $61.0M 1 Master Black Belt, 8 Black Belts, 79 Green Belts Audited by TYAD IRAC Sep 06 Lean Six Sigma at Tobyhanna Army Depot

6. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ 2006 Shingo Prize (Bronze) for AN/TPS-75 Radar System ✔ 2007 Shingo Nominee: AN/TPQ-36 Firefinder Antenna Transceiver Group Lean Six Sigma at Tobyhanna Army Depot

7. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Bring all related functions together ●LSS, 6S, ISO, Six Sigma, Quality, Process Engineering, Suggestion Program ●Creates synergy (cliché, but true) ✔ Cast a wide net ●Process Improvement Specialists in production directorates ●Managers and employees listen more to “their guys” ●Sometimes messy, but more effective ✔ Establish formal and informal networks ●LSS Starpoints ●LSS Starpoint Bulletins ●Identify and recognize informal leaders ●Share articles, success stories, problems, questions ✔ Anchor LSS to the existing culture ●Combine LSS with ISO audits, safety inspections, length of service, and CO’s Awards Walk Arounds ●Sustainment Managers Credit: John Kotter, Leading Change Successful Lessons Learned “What’s worked for us.”

8. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Stock a million carrots and a handful of sticks ●Certificates, photos, handshakes, e-mails, lanyards, coins, newspaper articles, meeting “recognition”, coffee and doughnuts ●Lean model cells ●NSPS objectives ●A picture is worth a thousand e-mails ●Punishment???? ✔ Use Shingo to drive improvement ●Great to win ●Simply competing = improvement –Mock evaluations –3 rd party KITA –“This is really serious stuff!” ●Lots of competitors in future ✔ Win them over early ●New Employee Orientation ●New Supervisor Training ●Formal training and Lean Keyword Cards Successful Lessons Learned “What’s worked for us.”

9. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Have a meaningful strategic focus ●CO and Deputy CO ●Supply chain ●Industrial support shops ●Non-traditional, but critical to all ✔ Straight talk ●FAQs and Pass Ups ●“What’s the Union think about all this?” ●“Why did Lean make me throw away a part?” ●“You’re just going to cut my hours.” ●“This is embarrassing.” ✔ Take your own medicine ●RIE on our own processes ●Standard work for PII ●6S for PII Successful Lessons Learned “What’s worked for us.”

10. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner ✔ Muscling changes through ✔ Rigid standardization ✔ Running before crawling, e.g., high tech Production Control Board ✔ Thinking you don’t need (some) outside consultancy ✔ Focusing on “event week” versus 7 week cycle ✔ Mixed messages “constant sustainment” versus “clean up for CG” ✔ Facilitators stronger than Team Leaders ✔ Assuming one “burning platform” for all ✔ “We can staff develop this stuff.” versus “They’ve got to do it for themselves.” ✔ Go easy on Toyota references Painful Lessons Learned “What hasn’t worked for us.”

11. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ISO 9001:2000/14001:2004 Facility Shingo Award Winner In Conclusion……….. It’s more about change management than it is about takt time calculations!