St. Bernard Project
“Our construction process simply wasn’t as effective as it could have been, and, as a result, we weren’t bringing as many families home,” said McCartney, director of construction.
Using Toyota Production System (TPS) techniques, “management boards” that track everything from volunteer/worker schedules to inventory to status reports on homes being rebuilt were displayed on the walls of the headquarters. Also, SBP staff and volunteers became committed to the TPS philosophy of no longer being “afraid” of problems; instead, it searches them out and attacks them thoughtfully with a mindset of constant improvement.
- The time it takes to rebuild a home dropped from an average of 116 days to 60 days – a 48 percent improvement;
- Amount of houses being rebuilt per month jumped from 8.6 to 12.8;
- Improved processes: the collaboration has consisted of sharing TPS know-how and working closely with St. Bernard Project’s professional staff, skilled construction supervisors and AmeriCorps members to improve homebuilding efficiencies.
“Before TPS, it was difficult to see problems – which caused wasted time and duplication of work,” said Toyota General Manager Jamie Bonini. “We want to instill a disciplined, but flexible construction model.”
Toyota Production System Support Center, Inc.
25 Atlantic Avenue
Erlanger, KY 41018 USA