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Unlock operational efficiency in large stationary assemblies with designs that flow and deliver

Duggan works with you to create a visual lean flow that is sustainable throughout your assembly.

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Why Duggan’s approach to large stationary assemblies is different

Many challenges regarding large stationary assemblies are not present in traditional manufacturing environments.

Chief among these issues is long product lead times, often in days, weeks or even months, and the many complex jobs that must be completed for the overall “product” to be considered finished.

It becomes arduous to schedule and deploy resources like material and manpower, as the predefined work sequence may be impossible to achieve given changes and schedule adjustments.

Duggan designs the process for large assemblies in rail, marine, oil and gas, aerospace, defense and space.

The longer and more complex your deliverable or project, the greater the risk of delays and surprises if your processes and personnel are not adequately organized. As an operations leader, you must ensure multiple teams and processes work seamlessly to deliver your project to your customer on time and within budget.

Common large stationary assemblies challenges

(and how Duggan solves them)

Challenge: Sustain the application of a lean system over months or years

Large assemblies can take months or years to complete, unlike higher-volume manufacturers that handle daily challenges. Creating a sustainable visual lean flow throughout the assembly is a unique challenge for our efforts.

Duggan’s Solution

Duggan works with your team to design an end-to-end solution. Our methodology uses lean design criteria to deliver mathematically the best outcome for your operation. Developing binary connections between areas such as subassemblies, fabrication and other suppliers to the main assemblies enables us to create the flow within your long lead time assemblies.

Challenge: Scale of the 
assembly itself

The traditional lean tactics can leave you confused when your product is of a large scale—whether a rail car, naval vessel or jet engine. Your product may or may not move during assembly. You may have struggled to give the assembly a clear sense of timing, and continually redirect labor when parts don’t arrive on time.

Duggan’s Solution

Duggan specializes in deploying operational excellence with large assemblies using innovative solutions to visualize whether the assembly can move. Our visual flow links assembly timelines back to supporting operations, such as machining and fabrication shops, to create an environment where every employee can clearly understand if they are on time to meet customer demand at all times without management telling them so. 

How we do it

At Duggan Associates, we take traditional lean training further with advanced courses, academic resources and hands-on support to transform organizations’ operations.

Specifically, here is what we do:

Conduct a planning event that provides you with a transformation plan.

Begin with executive training on operational excellence and the process of achieving it.

Work with your team to design an end-to-end solution with binary connections between areas such as subassemblies, fabrication and other suppliers for the primary assemblies, allowing us to create the flow within your long lead-time assemblies.

Train your team members on value stream design tools necessary in your business. 

Teach and deploy our mixed model and shared resources model to handle the complexities of real-life manufacturing. 

Generate a future state for flow based on our proven design criteria.

Follow a step-by-step, detailed implementation plan to achieve end-to-end value stream flow.

Ensure the reality on the production floor matches the future-state design we create together.

Let’s have a quick call

I have utilized Kevin Duggan at various times over the last 15 years, first at United Technologies Corporation and now at my current company, FMC Technologies. He demonstrates a very high level of competency in all things lean and operational excellence.

John Boyd
Senior Vice 

President, Global Products at TechnipFMC

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Large Stationary Assemblies

Frequently asked questions

How the approach works, and what it means for your operation.

Can work flow when the product stays in one place?

Yes. Flow can be designed around the sequence of work and the arrival of people, materials and information, even when the assembly itself remains stationary.

How do supporting shops connect to the main assembly?

We design clear connections between assembly and its supporting operations, including fabrication and subassembly. Those connections make timing and readiness visible.

Does this apply to builds lasting weeks or months?

Long lead-time assemblies are a focus of this service. The design gives teams a visible sequence and a way to understand progress toward customer delivery.

What types of assembly does Duggan work with?

Applications include rail, marine, aerospace, defense and oil and gas equipment. The approach reflects the product, supporting operations and delivery requirements.

What does implementation involve?

Duggan combines team education, future-state design and a detailed implementation plan. The work connects the design to how assembly and support teams operate each day.

Let’s discuss your assembly challenges

Tell us what you build, how long it takes and where parts, information or supporting work are holding up progress. We can discuss how the assembly sequence and its supporting operations can connect to make delivery progress visible.

Let's talk about
your large stationary assemblies challenge.

Let's talk about
your challenge.