1. Lean Manufacturing in New
Industries Yields Innovative
Industry Paradigms
Dr. Andrew Feller
VP – Manufacturing
IO Data Centers
How Manufacturing Capability Transformed Satellite Deployment for
the IRIDIUM System, and Data Center Infrastructure Deployment for
IO and its Customers

2. CREATING THE SHIFT
Manufacturing’s Contribution to Industry Innovation

3. Two Industry Transformations
Data Centers:
Modular IO.Anywhere
Aerospace:
IRIDIUM Space Vehicles

4. Background
• IO Data Centers – IO.Anywhere Production
• Arizona State University – Ph.D. IE (ISE/MSE)
• 2 Consulting Practices: IIS and KinetX
• Motorola – Satellite Production & Launch
• Boeing – 777 Design to Cost – JAD Work
Statement
• Boeing – $850M Sheet Metal Center
• Motorola/ASU – MS Fellowship/Internship
• Colt Industries – Turbine Repair IE
• ASU – Undergrad IE
• Johnston College – U of R: Liberal Arts

5. Two Industry Transformations
• Data Centers: Modular Production
IO.Anywhere Data Center Deployment
• Snowflake Construction  Standard Product
• Just-in-Time Deployment of Optimal Capacity
• Aerospace: Satellite Assembly & Launch
IRIDIUM Space Vehicle Constellation
• 18 month Integration & Test  1/Week TAKT Time
• 72 Satellites Launched in 1 Year

6. IO.Anywhere Production System
Striving for World Class Assembly at IO
OVERVIEW

7. Birth of a Module
http://www.youtube.com/watch?v=4JTZapUiAaA

8. Company Timeline
1st Modules ~3½ Yrs Ago

9. Big Data
Data is growing at 40 percent compound annual rate - 45ZB by 2020

10. How the Industry is Responding

11. Construction of More Data Centers

12. This Doesn’t Work Because…

13. It Takes Too Long
24+ MONTHS
Site Selection Negotiation Site Preparation Construction Commissioning

14. It Costs Too Much
+91%Pre-operational funding costs
+67%Fit-up costs
+46%Repair and maintenance costs
+30%Headcount and compensation
+19%Electricity costs
+19%CO2 emissions
5X
Over a 20 year life the operating cost of a
traditional data center is 5-times the capital
cost.
*all numbers are in comparison to Data Center 2.0 model for a 1MW data center

15. It Doesn’t Scale
Tier 3 Data Center - $$$$
CLOUD BACKUPERP
$$ $$$$
Tier 2 Tier 3Tier 1
Application
CPU
Storage

16. It is Inefficient
2.0+ Average
PUE
Disparate systems
+
“Snowflake” design
+
Lack of visibility

17. It is Insecure
Increasingly, companies are connecting
building energy management systems to
networks and to the Internet…
…the danger is that criminals could use
those connections to unlock doors, turn off
lights or sabotage data centers by turning
up the heat.
- Rachel King, CIO Journal, April 5, 2013

18. There is a Better Way

19. Motivation
Transform the paradigm of data
centers from a construction
project to a technology product
• Bring the efficiency of a
standard, optimized product to
market to meet the growing
demand for data center capacity
• Deliver this product with world
class development time, cycle
time, quality, and cost

20. Leading an Industry Transformation
• Construction Industry
• Uncharacterized Processes
• 18 Month Projects
• Punch-list Mentality
• Inadequate for Demand
• Heavy Capital Burden
• Each Project Unique
B
Existing
Capability
Desired
Competency
A
• Lean Module Production
• Characterized Processes
• 4 Week Assembly & Test
• Quality Designed In
• Scalable, Agile Response
• Just-in-Time Investment
• Standard Product enables
Optimization and Control
Data Centers

21. Manufactured+ + Factory tested + Purpose built
Standardized Form Factor

22. Safety Standard

23. Hot swappable components+
Concurrently Maintainable Design

24. Software Optimized

25. Starting the Lean Journey
• Factory Design
• CDR, PDR
• 1st Factory Setup
• 1st Modules
Built
• P1800
• D200
• D300
• All to PHX, NJE
• 55 Modules Built
• 1st Mfg. 101
Class
• UL Testing
2011 2012 2013 2014
• Factory Move to
DC
• 1st External Sales
• Opened Ohio
• Introduced
• P1500
• D400
• DSMOD
• 54 Modules Built
(63 Frames)
• 2nd Mfg. 101
Class
• UL Listing
• Factory Move to
CH
• Opened Singapore
• Introduced
• DHMOD
• 1st Outoor Install
• 122 Modules Built
(147 Frames)
• Lean Greenbelt
Class
• NO FACTORY
MOVE!
• Design Refresh
• Introducing ECO
• 6σ Classes
• ISO 9001

26. Installed Data Centers at a
Record Pace
• Ohio, Singapore:
Rapid DC Setup
at new facilities
• Incremental
Capacity on Short
Notice
• PBIO Fortrust, 1st
mods powered 3
weeks from order

27. Enablers – Starting the Journey
• Assembly 101 – State Funded
– Educating the construction worker
– Change the mindset
FROM: field engineering with ad-hoc
materials and punch lists
TO: Bills of Material, Pick Lists and
First Time Quality
• Onsite MEP Lean Workshop
• Onsite Custom Lean Greenbelt
Program for Leads
• QMS – ISO Registration

28. Assembly 101
• This course captured the following DLOs:
For Context For Lean For Quality, TPM and Safety
- Complete IO Business
Overview
- Global Business Pressures
- I/O Assembly Metrics and
Design
- Curriculum Outline and
Course Expectations.
- History of Lean
- What is Waste
- Fundamental Principles
- Visual Workplace
- Value Stream Mapping
- 5S + 1 (Safety)
- Set-up Reduction
- Pull and Flow
- TAKT Time
- Impact of Variability
- Cost of Quality
- Problem Solving Tools
- Safety impacts
- Safety principles and
guidelines
- Total Productive
Maintenance
- The Five TPM tools
- Information flows

29. The IRIDIUM® Satellite Production
System
IRIDIUM is a registered trademark and service mark of IRIDIUM LLC
Computer Integrated Manufacturing
Motorola, Chandler, Arizona

30. Motivation
• Deliver on the Promise of
Global Personal
Communications
• Bring Personal
Communications Within the
Reach of Every Human Being
in the World
• Produce a New Product With
Never Before Achieved
Development Time, Cycle
Time, Quality, and Cost

31. First to Market
• Iridium System Delivered for
Commercial Service on
November 1, 1998
• Eight Weeks Ahead of
Schedule
• Earned Incentive Bonus for
Early Delivery
Iridium is a registered trademark and service mark of Iridium IP LLC

32. Iridium System Overview
IRIDIUM is a registered trademark and service mark of IRIDIUM LLC

33. The Iridium Constellation
IRIDIUM is a registered trademark and service mark of IRIDIUM LLC
6 Planes, 11 Satellites per Plane

34. Created New Paradigm in Satellite
Manufacturing & Launch
• Launched at a
Record Pace:
– 72 Satellites in 12
Months, 12 Days
– 14 Satellites on 3
Launch Vehicles, from 3
Countries, in 13 Days
– 19 Consecutive
Successful Launches
• Satellite Integration and Test cycle time of 25 days vs.
industry standard of 12-18 months
• Pulse rate of 4.3 Days

35. Launched Constellation at a Record
Pace
• 72 Satellites in 12 Months,
12 Days
• 14 Satellites on 3 Launch
Vehicles, from 3 Countries,
in 13 Days
• 19 Consecutive Successful
Launches

36. Satellite Production & Launch
• Build and Test Satellites
• 3 Motorola Factories (Front-End, Middle, Back-End)
• 160 Sophisticated Electronic Assemblies
• Multi-Processor Parallel Computer
• Modems, Switches, Timing Units, Power Converters, ...
• Supplied Items: Bus, 12 Antennas, Solar Arrays,
Battery
• Software Flash Load: Vehicle Unique
• Launch Processing
• 3 Sites: California, China, Kazakhstan
• Battery Install, Fueling, Dispenser Mate

37. Leading an Industry Transformation
• Craft Industry
• Uncharacterized Processes
• 18 Month Integration & Test
• Quality Tested In
• Inadequate for Commercial SV
B
Existing
Capability
Desired
Competency
A
• Lean SV Production
• Characterized Processes
• 21 Day Integration & Test
• Quality Designed In
• Necessary for Commercial
Success of IRIDIUM
AEROSPACE

38. Manufacturing Leadership
• Everything it takes to bring a product to the
customer
• Manufacturing pulls the design
• Coordinates with suppliers, internal resources,
and customers
• Process oriented
• Able to get things done

39. Worth Our Consideration…
• The importance of taking a total supply chain perspective
and extending concurrent engineering activities beyond
organizational boundaries
• That most organizations are designed to subliminally kill
the concurrent efforts and teamwork their rhetoric
supports
• The line between product development and
manufacturing has blurred:
• Product cycles are shorter
• Production processes considered during design
• Quality is design dependent

40. Keys to Success
• Open Communication and Collaboration Across
Organizational Boundaries
• Courage to Question the Status Quo
• Willingness and Support to Try Something
Different
• Tool Development

41. Challenging the Status Quo
• Establishing a Reach-Out Goal:
“5 Day Dock-to-Dock”
• Five years prior we were crazy
• Four years prior just reckless
• Three years prior: ”Is that 5-24 hour days”
• Two years prior reality set in, plans paid off:
• Traded risk for schedule
• Managed test bottleneck operations
• Eliminated marginally required tests
• Production Year: 4.3 Day Pulse Rate –
23 Day Cycle Time

42. Obstacles to Progress
•Hierarchical organizational structure
•Sequential policies and procedures
•Culture that associates status with position rather
than knowledge
•Legacy thinking
• Our own “Rules of Thumb”
•Inadequate social skills
•Lack of vision

43. The Value of a Crises
• One of the Few Times There is A Clear Mission
and Vision
• Processes are Naturally Streamlined
• Easy for the Individual to Determine Their
Commitment

44. The Vision to Transform an Industry
• Vision
• To design, develop, and operate the lowest cost
product delivery mechanism in the industry
• Team Mission
• Influence the design
• Plan and implement steady state operations
• Develop core competencies for long-term competitive
advantage
• Guiding Principles
• Product designs consist of both parts and processes
• Quality is inherent in the design
• 5 Day Dock to Dock Cycle-Time

45. Approach to the Development
Process
• Focus on Optimizing the Entire Supply Chain
• Establish Clear Vision, Mission, and Values
• Predict Quality During Development
• Predict Cycle Time During Development
• Consider Up and Down Stream Processes in All
Design Decisions

46. Strategies
• 6 Sigma analysis of electrical & mechanical designs
• Composite design metrics for manufacturability:
(DTUPC, 6 sigma scorecard, standard parts, standard
processes, part count, board density, etc.)
• Collaborative Parts Management
• Process Focus and Modeling
• “5 Day Dock-to-Dock” Cycle-Time Budget
• Benchmarking commercial industries for processing
and handling ideas
• Awareness, Education, and Awards
• Brokerage and Influence

47. Techniques & Tools
• DTUPC Database
• Process Characterization & Experiment Design
• Modeling
• Process Icon and Bill of Process Database
• “Virtual Factory” Simulation
• 3-D Solids
• Factory Data Flow: Inter- and Intra- Company
• Collaborative Equipment Design
• DFM Guidelines for the Supply Chain
• 0 Based CIM: “Buy & Tie” Systems

48. Standard for Process Models from the Air Force Integrated Computer Aided
Manufacturing (ICAM) Program. Icam-DEF Method 0 → IDEF0
Verb/Noun
Phrase
Activity Box
Input(s) Output(s)
Mechanism
Control
Concept Tree Relation Tree
T
Activity Entity
T
E-E A-A E-A
Branch
Join
Seq
Dom
Support
I
C
O
M
Information
Layer
Resource
Layer
Material
Flow
OO
Petri Net
Simulation
CG AI Meta-model
(Box) (Arrow)
Ref Ref
Prior Research – Process Modeling & Analysis:
Extension of IDEF0 Modeling

49. Material Flow
Resources and Facilities
Cast Mach Inspect Move Assemble
Company A Company B
IT & IE
ME & IE
Planning, Finance & IE
Enterprise Analysis in 3 Layers
Information and Control Flow
IE as System Integrator

50. Material Flow
Resources and Facilities
Information and Control Flow
• Product and Process Specifications
• Product Changes and Updates
• Planning and Scheduling
• Kanban Signaling/WIP Tracking
+ Process Control
• Cycle Time/TAKT Time
• Process Variability and Control
• As-Built Configuration Data
• Environmental and Safety Factors
• Material Requirements
• Handling Requirements
• Inventory Targets
• Logistics
• Throughput Capacity and Capability
• Transportation and Distribution Equipment
• Containers and Recyclables
• Staffing Requirements
Supply Chain Design Blends all 3+

51. 3.0
ASSEMBLE & ATTACH RF C ABLES TO BEAMFORMER
1200
A Graphical Look At:
Qualif ication Initial Production Steady State
3.0
Electro-mechanically connect RF cables
between the T/R Modules and the
beamf ormer (122), and the driv e modules
and the beamf ormer (32)
Controlled torques?
Cable sleev es are marked to insure correct destination
Dif f icult handling of .047 diameter cable.
Inv estigate use of "handi-f orm" f ormable cable material (Ni plated jacket)
(Possibility of preconf iguring a harness?)
Issues/Comments
Assemble Beamf ormer to panel.
ComesFrom Process List
Attach Velcro Strips
GoesTo Process List
Process documentation/v isual aid
(Paperless)
1
1
Documentation stamp/barcode
Inv entory status
154 RF Cables
Hand tools
Panel with RF cables
People
Required
Space (ft)
L W H
Min
Max
Process ControlInformation IN Information OUT
New Parts IN
Description
Cycle Time - Hours
Product OUT
Resource OUT
Environmental Byproducts
Facility Requirements
Safety Issues
Resource IN
Assemble/InstallPanel with beamf ormer
Previous Product IN
Hand tools
Electro-mechanically connect both ends of each RF
cable.
Self inspect f or correct designation.
Activities
6/23/93 5 D AY DOCK TO DOCKIRIDIUM M ANUFACTURING BILL OF PROCESS
Information
Material
Resources
Control Rules
Facilities
Electro-mechanically connect RF cables
between the T/R Modules and the
Beam-former (122), and the drive modules
and the beam-former (32)
Description
Cycle Time - Hours
Assemble/Install
Process Data
Application: The Process Icon

52. Supply Chain Bill of Processes
3.26 Certified Assembler
Supplier A
Supplier B
Supplier C
Bill of Process
Database
LocationProcess Name
Sequence
Level
Cycle
Time Person - Process
SunnyvalePack and Prep Battery5790 4 Kevin Bilger
Launch SiteLAUNCH SITE HEADER PAGE6000 0 JORDAN
Launch SiteTransport SV/Dispenser to Launch Complex6057 8 Jeff Finan
BostonThermal Cycle1280 52 Paul Babbit
ChandlerSV Liveness Test5070 6 Hyrie Bysal
Launch SiteSV Confidence Test6020 4 John McBride
BostonAttach Velcro Strips to Panel1210 0.7 Richard Russo
BostonDispenseAdhesive & Assemble Patches1040 .575 Richard Russo
BostonAssemble and Bond T/R Modules1060 .57 Richard Russo
AustinACS Hardware Installation (NADIR)2280 16 John Tiemann
AustinEPS Panel/IBE Assembly & Test2230 8 John Tiemann
BostonAssemble Control Modules1160 0.2 Richard Russo
ChandlerPayload/CES Panel Assembly - Station 54080 6.6 Don Jensen
AustinNADIR-Propulsion System Assembly222 6.07 Assembler(certified)
AustinNADIR MODULE,Propulsion System-Weld219.1 5.75 Machine Operator
AustinCOM MODULE,Propulsion System-Weld229.1 5.75 Machine Operator
AustinBUS MODULE,Propulsion System-Weld239.1 4.95 Machine Operator
BostonAttach Patch Hold Down Fixture1050 0.2 Richard Russo
BostonLay Thermal Blanket Over Panel Back1230 0.2 Richard Russo
SunnyvaleShipFrom Sunnyvale5800 168 Jordan Snyder
Launch SiteReceive Flight Battery Radiator Assembly6035 2 John McBride
BostonElement Test1260 16 Paul Babbit
BostonBond and Assemble Drive Modules1070 1.4 Richard Russo
BostonBond and Assemble Power Regulators1090 3 Richard Russo
AustinBUS MODULE-Propulsion System Purge and Seal243 0.91 Assembler
BostonCalibration Verify1290 16 Paul Babbit
Launch SiteCharge Batteries6120 10 John McBride
BostonClean Panel and Pack1330 1.0 Richard Russo
ChandlerCS FunctionalTest - Station 84110 48 Mike Monteilh
ChandlerPropellant Line Connection5030 7 Hyrie Bysal
ChandlerPropellant Line Connection - Welding5031 7 Hyrie Bysal
BostonAttach R.F. Cables and Flex's to T/R modules1130 7.0 Richard Russo
BostonAssemble P/R Flex1140 0.5 Richard Russo
BostonCure & Remove Fixture1100 168 Richard Russo
AustinShip CM Structure to Comm Space2780 1 John Tiemann
BostonShip MMA to Comm Space1900 24 Paul Babbit
AustinNADIR-Receiving220
Bill of Process
1230 Lay Thermal Blanket Over Panel Back 0.2 Boston Richard Russo

53. Application: The Process Icon
ASSEMBLE & ATTACH RF C ABLES TO BEAMFORMER
1200
A Graphical Look At:
Qualif ication Initial Production Steady State
3.0
Electro-mechanically connect RF cables
between the T/R Modules and the
beamf ormer (122), and the driv e modules
and the beamf ormer (32)
Controlled torques?
Cable sleev es are marked to insure correct destination
Dif f icult handling of .047 diameter cable.
Inv estigate use of "handi-f orm" f ormable cable material (Ni plated jacket)
(Possibility of preconf iguring a harness?)
Issues/Comments
Assemble Beamf ormer to panel.
ComesFrom Process List
Attach Velcro Strips
GoesTo Process List
Process documentation/v isual aid
(Paperless)
1
1
Documentation stamp/barcode
Inv entory status
154 RF Cables
Hand tools
Panel with RF cables
People
Required
Space (ft)
L W H
Min
Max
Process ControlInformation IN Information OUT
New Parts IN
Description
Cycle Time - Hours
Product OUT
Resource OUT
Environmental Byproducts
Facility Requirements
Safety Issues
Resource IN
Assemble/InstallPanel with beamf ormer
Previous Product IN
Hand tools
Electro-mechanically connect both ends of each RF
cable.
Self inspect f or correct designation.
Activities
6/23/93 5 D AY DOCK TO DOCKIRIDIUM M ANUFACTURING BILL OF PROCESS
Information
Material
Resources
Control Rules
Facilities
3.0
Electro-mechanically connect RF cables
between the T/R Modules and the
Beam-former (122), and the drive modules
and the beam-former (32)
Description
Cycle Time - Hours
Assemble/Install
Process Data

54. Supply Chain Optimization
Transactional
Relationship
Info-Sharing
Relationship
Collaborative
Relationship
• Leveraged information availability
– Design Metrics, Planning and Execution Data
• Created alternative business agreements/models
– Vendor Managed Inventory (VMI)
– Service Level Agreements (SLA)
– Performance Incentives
– Kanban Signals
• Implemented Multi-echelon Resource Optimization
– Better analytical methods:
• Algorithms and software tools for optimization of
inventory vs. service level given variability in demand
and supply
• Statistical analysis
• Capacity planning
• Simulation

55. • Total Supply Chain Performance, Capability, & Resource Analysis
– Iridium Satellite Virtual Factory
Bus
Comm Mod
Motorola Final
FL
W U
Stocker
AD
T U
Load
AD
T U
Unload
3Trains
UD
Area Stocker 3 Test 368.29 seconds travel time
start
V
F
L W
Que 12
TCR
Receive
Furnace
demand
a
b
c
a
b
demand
a b c
a
b
c
R C T
Send
Furnace
R C T
Send
Furnace
TCR
Receive
Furnace
R C T
Send
Furnace
3 Trains
TCR
Receive
Furnace
R C T
Send
Furnace
MMASubassemblies
Raytheon Boston
X-Link Antennas
G-W Antennas
CM Structure
Panels
Nadir
Motorola Initial
FL
W U
Stocker
AD
T U
Load
AD
T U
Unload
3Trains
UD
Area Stocker 3 Test 368.29 seconds travel time
start
V
F
L W
Que 12
TCR
Receive
Furnace
demand
a
b
c
a
b
demand
a b c
a
b
c
R C T
Send
Furnace
R C T
Send
Furnace
TCR
Receive
Furnace
R C T
Send
Furnace
3 Trains
TCR
Receive
Furnace
R C T
Send
Furnace
FL
W U
Stocker
AD
T U
Load
AD
T U
Unload
3Trains
UD
Area Stocker 3 Test 368.29 seconds travel time
start
V
F
L W
Que 12
TCR
Receive
Furnace
demand
a
b
c
a
b
demand
a b c
a
b
c
R C T
Send
Furnace
R C T
Send
Furnace
TCR
Receive
Furnace
R C T
Send
Furnace
3 Trains
TCR
Receive
Furnace
R C T
Send
Furnace
SV
Subassemblies Battery Radiator Assembly
To
Orbit
Lockheed Sunnyvale
Launch
FL
W U
Stocker
AD
T U
Load
AD
T U
Unload
3Trains
UD
Area Stocker 3 Test 368.29 seconds travel time
start
V
F
L W
Que 12
TCR
Receive
Furnace
demand
a
b
c
a
b
demand
a b c
a
b
c
R C T
Send
Furnace
R C T
Send
Furnace
TCR
Receive
Furnace
R C T
Send
Furnace
3 Trains
TCR
Receive
Furnace
R C T
Send
Furnace
FL
W U
Stocker
AD
T U
Load
AD
T U
Unload
3Trains
UD
Area Stocker 3 Test 368.29 seconds travel time
start
V
F
L W
Que 12
TCR
Receive
Furnace
demand
a
b
c
a
b
demand
a b c
a
b
c
R C T
Send
Furnace
R C T
Send
Furnace
TCR
Receive
Furnace
R C T
Send
Furnace
3 Trains
TCR
Receive
Furnace
R C T
Send
Furnace
Launched
72 Satellites
in 1 Year
CM Struct
Panels
Bus
Nadir
ACS, ...
Lockheed Nashua
FL
W U
Stocker
AD
T U
Load
AD
T U
Unload
3 Trains
UD
Area Stocker 3 Test 368.29 seconds travel time
start
V
F
L W
Que 12
TCR
Receive
Furnace
demand
a
b
c
a
b
demand
a b c
a
b
c
R C T
Send
Furnace
R C T
Send
Furnace
TCR
Receive
Furnace
R C T
Send
Furnace
3 Trains
TCR
Receive
Furnace
R C T
Send
Furnace
CM Str. Container
Nadir Container
MMA Container
Resources:
CM Dolly
Bus Container
Bus Dolly
MMA A Frames
SV Container
SV Dolly
Locations:
Austin
Chandler
Boston
China
Russia
California
Virtual Factory
Virtual Factory:
Supply Chain Simulation

56. 5 Day Dock-to-Dock Budget
Treating Time Like Money
Process Description Budget Actual Var Part Process Actions 0
Hour s Hour s Hour s Owner Owner
Receive Comm
Module
Receive CM and
accessories from
Comm Spaceand
prepformate
2.0 2.0 0.0 DonJensen (Comm Space) Andrew Fell er
Formeda Handling
Team to cometoan
agreementona
common handli ng
vi sion
Receive Bus
Receive BUS and
accessories from
LockheedAustin
andprep for mate
3.0 3.0 0.0
BobGonzal es (LAD)
Bill Vaubel (LAD)
Andrew Fell er
Formeda Handling
Team to cometoan
agreementona
common handli ng
vi sion
Mechani cal Mate:
CMand Bus
Physical assembly
of the Comm Module
andtheBUS secti on
2.0 5.0 3.0
Dave Stewart(LMSC)
Herb Liebelt (LMSC)
Bill Patterson(LAD)
JordanSnyder
Issuedreporton Mech
Mate Process09/06/93
PropellantLine
Connection and
Test
Connect all lines
between the two
sections and
performl eak tests
7.0 7.0 0.0
Irv Bernard(LMSC)
Bill Patterson(LAD)
Hyrie Bysal
Studying cryogenic fit
versusorbital weld,
have baselinerouti ng
in place
Electrical Mate:
CMand Bus
Electrically connect
powerlines and
si gnal connectors
between CM and
BUS
7.0 7.0 0.0
Dixon Ng(LMSC)
Noel Vil lanueva(LMSC)
Jack Stroman(LAD)
John Vekich
Identi fied the 7 electrical
connecti ons
Instal l Thermal
Blankets
Instal l necessary
thermal blankets
ontomatedCM and
BUS
2.0 2.0 0.0
Ji mSchirle (LMSC)
Kevin Freund(LMSC)
Dave Di ppre notyetfully investi gated
SVLivenessTest
SixSigma
verificati onofall SV
level connections
6.0 6.0 0.0
Helmuth Drosdat(LMSC)
DonJaques (LAD)
John Zukoski notyetfully investi gated
Instal l Solar Arrays
Attachsolar arrays
to drives infolded
positi on, and lock
HDRM
mechani sms
6.0 8.0 2.0
Kevin Bilger(LMSC)
PatrickHart (LMSC)
RobBlack(LMSC)
HarveyHasegawa (LMSC)
DariusChung(LMSC)
John Zukoski
In processofwriting
report on Solar Array
CompositeDesign
Analysis
SVPackandShip
Prepare fully
assembl edSV for
shipping to
destinati onl aunch
si teorstorage
4.0 4.0 0.0 Greg Selzer (LMSC) JeffFinan
Formeda Handling
Team to cometoan
agreementona
common handli ng
vi sion
Total 39.0 44.0 5.0
5 Day Dock to Dock Processi ng Ti me Variance
Process
Processing Time Variance inHours
-4.0 -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0 4.0
Receive Comm
Module
Receive Bus
Mechani cal Mate:CM
andBus
PropellantLine
Connection and Test
Electrical Mate:
CMand Bus
Instal l Thermal
Blankets
SVLivenessTest
Instal l Solar Arrays
SVPackandShip
BudgetVari ance

57. Technology Investments
• Discrete Event Simulation
• Advanced Solids Modeling
• Advanced Workstations & Networks
• Database: Prototyping to Production
• Factory Information Systems
• Software Configuration Management Version Control
System
• WAN and Intranet

58. Influence
• More important than technology
• Advantages of technology must be demonstrated and
invested in
• People make or break technology introduction - invest in
people

59. Influence: What Worked
• Creating and Establishing a Vision
• Focusing on Non-Technical Skills
• Public Speaking
• Feedback
• Understanding Personal Styles
• Writing
• Lateral Thinking
• Give ‘til it hurts
• On-site Liaisons, Coaching and Technical Support
• Workshops - Redefining the Customer
• Awards and Recognition

60. Challenges
• Technology Introduction and Integration
• Managing Configuration Change:
• Key Driver for Manufacturing Systems
• Test Operations and Data Management
• Balancing the Supply Chain within Rigid Contractual
Constraints

61. Manufacturing’s Vision!
• To design, develop, implement, (and transform) industrial
processes
• Influence Designs
• Focus the Enterprise on Process
• Develop Core Competencies
• Provide the guiding context (why?) for technology
implementation

62. Closing Thoughts
• Create Reach Out Goals
• In the Absence of Meaningful Metrics, Use Time
• Spend as Much Effort on Relationships as Technical Issues
• Create Clear and Succinct Vision
https://www.youtube.com/watch?v=4mHNYwLbUI0

63. The Spirit of Innovation

64. Thank You!
Please complete the session survey at:
ame.org/survey
Session Code: ThP-39
Lean Manufacturing in New Industries Yields
Innovative Industry Paradigms
Dr. Andrew Feller
IO Data Centers
af@io.com