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Scrum For Full-Scale Manufacturing: How The Shop Floor Can Keep Up With Scrum R&D

Scrum-for-Full-Scale-Manufacturing

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0% found this document useful (0 votes)
109 views34 pages

Scrum For Full-Scale Manufacturing: How The Shop Floor Can Keep Up With Scrum R&D

Scrum-for-Full-Scale-Manufacturing

Uploaded by

FLINVE
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Scrum for Full-Scale Manufacturing

How the Shop Floor Can Keep Up with Scrum R&D

Hosts: Alex Brown  


Joe Justice

© 2014 Scrum Inc.


© 2011 Scrum Inc.
: Who We Are
Scrum Inc. is the Agile leadership company of Dr. Jeff Sutherland,
co-creator of Scrum. We are based in Cambridge, MA.

We maintain the Scrum methodology by:


•  Capturing and codifying evolving best practices
•  Conducting original research on organizational behavior
•  Adapting the methodology to an ever-expanding set of
industries, processes and business challenges
Alex  Brown   Joe  Jus6ce  

We also help companies achieve the full benefits of Scrum through our
comprehensive suite of support services:
•  Training (Scrum Master, Product Owner, Agile Leadership, online courses, etc.)
•  Consulting (linking Scrum and business strategy, customizing Scrum)
•  Coaching (hands-on support to Scrum teams)
•  Publishing and new content development

We run our services company using Scrum as the primary management


framework, making us a living laboratory on the cutting edge of “Enterprise

© 2014 Scrum Inc.


Scrum”

Find  out  more  at  www.scruminc.com.    


Agenda
•  Discuss Lean as a jumping off point
•  Lean is great but it can sub-optimize and increase cost
to make changes
•  Present four XM principles to speed up the
manufacturing line
•  Scrum teams as lean cells
•  Contract-first design
•  Shorten supply chains
•  Keep the line flexible
•  Address why you CAN do this (debunk objections)
•  Show tooling and suppliers that make it possible
•  Share examples from companies that have succeeded
•  Tait Radio

© 2014 Scrum Inc.


•  Rocket Bunny (WIKISPEED and Tesla)
Scrum in Manufacturing: A Motivational Example

F-35 “Joint Strike Fighter” – SAAB JAS 39E “Gripen” –


Traditional Design Agile Design

•  $143 billion over budget •  Cumulative program cost of


$15 billion
•  At least another year late
(final systems integration) •  New iteration of all systems
released every 6 months
•  Cost of Navy F-35C grew from
$273 million in 2014 to $337 •  $43M cost1 (20% of F-35)

© 2014 Scrum Inc.


million by 2015
1. According to Jane’s Aviation Weekly, the Gripen
is the world’s most cost-effective military aircraft
Extreme Manufacturing (XM) Scrum   XP  

OOA  

I.  Scrum  Organiza6on   II.  XP  Engineering    


a.  Roles  and  Responsibili6es   Principles  
b.  Sprints/Itera6ve  Design   a.  User  Stories  
c.  Make  Work  Visible   b.  Pairing  and  Swarming  
d.  Measure  Velocity   c.  Test  Driven  Development  
e.  Con6nuous      
Improvement  (Lean)  
“XM”  

Morale  is  a  
mul6plier  for  
Velocity!   III.  Object-­‐Oriented  Architecture  
a.  Modular  Components  
b.  Contract-­‐First  Design   IV.  Line  Setup  
c.  Design  PaEerns   a.  Machine  Ra6onaliza6on  
d.  Re-­‐use  and  Inheritance  

© 2014 Scrum Inc.


b.  Material  Selec6on  
c.  Line  Skills  Selec6on  
Scale as Competitive Advantage is Declining
If You Aren’t Making Millions of the Exact Same Product,
Speed of Changeover is More Important

Major Auto Company’s CNC Machine: Startup Auto Company’s CNC Machine:
$100,000,000 $2,000

Capacity: One dye per day Capacity: One dye per day

That’s 1/50,000th the cost

© 2014 Scrum Inc.


Source: www.wikispeed.org
Lean Thinking is the Essential Foundation

Receiving Milling Welding Painting Assembly Shipping

! ! ! ! !

Lean: Take a systematic view to maximize value delivery across


the entire “value stream” rather than focusing on just one step

Lean: Any activity that does not add value to the end product is
WASTE and should be eliminated from the process

Lean: Identify root causes of waste and eliminate them rather


than treating symptoms

Lean: Build quality into each step of the manufacturing process


to avoid the waste of rework

However, Lean can make it more expensive to change the line.

© 2014 Scrum Inc.


As speed to change becomes more important than scale, this
risks sub-optimizing lifecycle value delivery
XM Principles and Practices to Build into the
Manufacturing Line

A  •  Use Scrum teams as lean cells – Scrum for


organization allows teams to improve faster and
implement more lean improvements in the same
timeframe

B  •  Object-Oriented Architecture – be willing to


over-build at key points to allow greater
flexibility for the overall product and leverage
design patterns

C  •  Shorten supply chains – longer supply chains


are more prone to disruption and slower to
respond. Short ones can turn around iterations
faster

D  •  Keep the line flexible – make it as easy as

© 2014 Scrum Inc.


practical to reformat the line in response to
process improvement experiments
A  
Scrum Teams as Lean Cells Scrum   XP  

OOA  

Sprint provides team


improvement
cadence in addition
to Takt time cadence

Retrospective results
in at least one Kaizen
event per sprint

Pre-shift Daily Scrum


helps align cell
members and
coordinate across
cells to achieve day’s
production goals

© 2014 Scrum Inc.


B   Object-Oriented Architecture: Scrum   XP  
Contract-First Design OOA  

•  Volvo’s SPA, or Scalable Product Architecture, announced August 13th, 2014


•  This Contract-First Design reduces cost to produce many descendent designs

© 2014 Scrum Inc.


•  The next step? Reduce the cost to change the manufacturing process
•  For that, we need to add Known Stable Interfaces
B   Object-Oriented Architecture: Scrum   XP  
Known Stable Interfaces OOA  

Pre-negotiated
physical and data
connections permit
greater design
versatility, and loose
production coupling

Interfaces
deliberately over-
designed to reduce
need for disruptive
re-negotiation

© 2014 Scrum Inc.


B   Object-Oriented Architecture Scrum   XP  
Design Patterns and Inheritance OOA  

•  Don’t re-invent the wheel


•  If a proven solution has worked well in the
past, start with that and modify as needed

•  Reduce complexity – Find


solutions that work for multiple
aspects of the problem
•  Eg. If a particular bolt works as a
fastener in one location, use the
same bolt in all similar situations

© 2014 Scrum Inc.


C   Shorten Supply Chains for Added
Responsiveness
Long and complicated Supply Chains increase…

WIP Inventory and


Working Capital

Supply Chain Risk

Feedback Cycles

© 2014 Scrum Inc.


D  
Keep the Line Flexible Scrum   XP  

OOA  

Long changeover time to switch


the physical line limits the ability
to experiment with new process
improvements

Designing the line equipment to


be flexible accelerates
continuous improvement and
supports multi-product
manufacturing

Some companies go as far as to


mount all equipment on casters
to drive flexibility

© 2014 Scrum Inc.


Top Reasons Companies Say They Can’t Do This

“Our product is too complicated to not plan


1   everything meticulously in advance”
I. Fundamental
misunderstanding
“Our quality expectations are too high to not of agile principles
2  
follow a documented and unvarying plan”

“We have already made large investments II. Current


3  
in fixed machinery and tooling” impediments that
can be addressed
“Our product design is too tightly coupled iteratively over
4   to iterate modules without changing the time
entire design”

“Our vendors are not Agile enough to


5  
support this approach” III. Key issues
requiring creative
“Key steps of the manufacturing process thinking to solve

© 2014 Scrum Inc.


6  
require too long a lead time to fit in sprints ”
5/6   Even Cheaper for Plastics:
Protomold

•  Prototype parts or molds same-day


•  Volume parts or molds same-week
•  $1-$10k per mold

© 2014 Scrum Inc.


5   Suppliers that Make this Possible:
Electronics

RushPCB RuggedCircuits

•  2-layer circuit boards in 5 days •  Military and aviation grade


for $10 hardening
•  Up to 8 layer circuit boards •  In stock same day $40
•  USB programmable, Arduino

© 2014 Scrum Inc.


compatible
5   Partners that Make this Possible:
Full Ecosystem
Local Motors

© 2014 Scrum Inc.


5/6  
A Lean Production Cell:

Capable of one part every six seconds.


The cost to change?
New metal molds, called dies, up to 40 tons each

© 2014 Scrum Inc.


5/6   Suppliers for your Production Molds:
Molds Shipped to you Within a Sprint

3d Green Sand Casting

•  Volume metal castings same-week


•  Fastest, cheapest, quality metal tooling

© 2014 Scrum Inc.


5/6   Even Better, Make your own Molds:
Make your own molds inside each sprint

Subtractive Rapid Prototyping (SRP)

•  Roland MDX-40A •  Okuma M560-V


•  $8k USD, 12”x12”x4” •  $120k USD, 41”x22”x18”
•  Quiet for desk office use •  Requires trained operator

© 2014 Scrum Inc.


•  28x gives similar work area •  Durable, but costly repairs
5/6  
Reducing the Time to Change Molds:
Change your Production Each Sprint with your Own Molds

Globe Industries

•  Line-Speed composites: 17minutes part-to-part.


•  1 minute tool exchange time.

© 2014 Scrum Inc.


•  $1M USD tool.
5/6  
Even Better, Entirely
Skip Molds and Press

Cincinnati BAAM

•  Production structural parts same day


•  Carbon Filament reinforced 3d printing

© 2014 Scrum Inc.


Example: Tait Radio
Christchurch, New Zealand

© 2014 Scrum Inc.


© 2014 Scrum Inc.
XM = Scrum In Hardware Design

© 2014 Scrum Inc.


XM = Scrum In Mass Manufacturing

© 2014 Scrum Inc.


XM Requires XP To Be Safe At High Speed

© 2014 Scrum Inc.


Whole Company Agility: The Retrospective

© 2014 Scrum Inc.


Profile of a Disruptive Supplier:
Rocket Bunny and Liberty Walk

© 2014 Scrum Inc.


From Idea to Customer in 1 Sprint

1)  Scan   2)  CAD,  post  to  Facebook   3)  Machine  Foam  Mold  

4)  Build  and  Race   5)  Polish  and  Show   6)  Sell  Sell  Sell  

© 2014 Scrum Inc.


Suppliers  are  doing  this  now.    If  your  suppliers  can’t  do  this…find  different  suppliers  
Conclusions
•  As market responsiveness becomes more important than
scale, adding agility to manufacturing is essential
•  XM enhances Lean with Scrum and other Agile practices to
the physical R&D and manufacturing world
•  Four practices should be of interest to manufacturers:
•  Scrum teams as Lean cells
•  Contract-First Design
•  Shorten supply chains
•  Keep the line flexible

•  All of the reasons you think you can’t do this have already
been solved
•  Companies are starting to leverage Agile manufacturing to

© 2014 Scrum Inc.


succeed in the market. Is your competitor one of them?
Ques6ons?  

© 2014 Scrum Inc.


Stay Connected
Scruminc.com  
•  For up coming events, new content releases, and more!  
ScrumLab  
•  articles, online courses, tools, and papers on all things scrum  
•  www.scruminc.com/scrumlab  
Blog  
•  http://www.scruminc.com/category/blog/
Online Courses  
•  advance your scrum with our online courses. Visit the Scrumlab
store to view upcoming topics.  
Twitter, Facebook, and G+  
•  @ScrumInc, @jeffsutherland, scrum and scrum inc.

2014Scrum
©2012 Inc.
ScrumInc.
34

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