Thales Defense & Security in Clarksburg, MD, recently embarked on a Lean transformation to improve its CNR radio assembly lines. The leadership team faced challenges with cluttered workstations, excess inventory on benches, limited standardization, and long cycle times. Through a structured Lean approach, they redesigned the production flow into a one-piece flow system, stood up visual management boards, and built a robust material delivery system with supermarkets and water spiders.

The presentation will take attendees inside this journey from the “before state” of bottlenecks and inconsistent management practices, to the redesigned “future state” that now features:

• One-Piece Flow Assembly: Faster, more organized lines with clear material movement.
• Visual Management Systems: Hour-by-hour boards, tiered huddles, and real-time performance tracking to drive accountability.
• Material Delivery & Supermarkets: Fully labeled bins and racks that enable efficient replenishment and accuracy.
• Leadership Engagement: Building a Core Team capable of sustaining Lean improvements and mentoring others.

The Thales team will share measurable results in cycle time reduction, staffing optimization, engagement, and demonstrate how Lean can rapidly transform a defense manufacturing environment.

What Attendees Will See on the Tour:

The tour will bring the story to life by walking attendees directly through the improved CNR assembly area. Expect to see:

• Before & After Contrasts: Stations that were once cluttered are now standardized with visual cues, tool organization, and clear product flow.
• Hour-by-Hour Boards in Action: Color-coded and line-specific boards being updated in real time by operators, showing production targets, staffing assignments, and progress at a glance.
• Supermarket & Material Delivery: Water spiders restocking bins with precision using rack-shelf-bin labels and color-coded tags — a living example of pull systems and visual control.
• Operator Engagement: Teams participating in daily huddles, reviewing performance, and surfacing blockers for rapid resolution.
• Next Steps in Progress: Expansion efforts into additional lines, reinforcing that this is not a one-off project but part of a larger enterprise-wide Lean journey.

This will not just be a “show and tell”. Attendees will experience how Lean concepts have been embedded into daily operations, creating a system that improves flow, accountability, and culture across the shop floor.