Global Equipment Repair and Rehabilitation Loops

Imagine not having what you need at a moment where lives are at risk.

The challenge facing the U.S. Army was having troops redeploy without their individualized equipment.  Not having the equipment customized to their individual capabilities and needs resulted in delays due to re-training or waiting on specific equipment.

The equipment, such as vehicles and communications gear, would arrive home in a variety of battle-worn conditions.  This equipment needed to be repaired in time to redeploy with the troops on their next tour of duty.  When I started this effort the troops were redeploying in 180 days and the equipment repair was taking up to 400 days.

At the beginning leadership expressed little hope for improvement. 

We created a strategy to align the teams across locations.  To drive action we employed a variety of approaches including Shingo-style mapping, rapid problem solving, 5S systems, and team-building improvements. During this multi-site project we developed a common metrics dashboard and implemented a system to replicate improvements from site to site.

Within 14 months we had reduced process cycle time by 80%.  Troops could deploy with their same equipment which gave them a great sense of security going overseas.

As an added benefit this effort saved the Army hundreds of millions of dollars in efficiencies found during our work.

Morale skyrocketed!