At the shop level, Boeing continues its focus on lean manufacturing. Emphasis is on innovation and solving problems without adding new, large machines, additional workers or other heavy spending. Machine maintenance is constant, so breakdowns are minimized. Work also is divided so employees cover jobs that require decision-making while machines take over repetitive work. This brings lean techniques to disciplines such as raw materials supply, packaging and transportation.
Effort is applied where it can serve the most benefit, such as reducing bottlenecks.
In addition to lower costs, lean manufacturing improves quality, safety and worker morale, Boeing said. It also helps reduce manufacturing cycle time and inventory. Application of lean techniques has had significant results. Workflow rate soared to 138,000 parts per year from 58,000. This allowed Boeing to bring in outside work making replacement floor panels for Delta Air Lines.