01 — The clock
Rails were needed as fast as we could make them
There was no comfortable release schedule on this job. The requirement was simply that rail arrive as quickly as we could fabricate and anodize it — for two years, without a gap.
That is two clocks, not one. Cut, cope, drill and weld in Logan. Then every piece leaves the building, goes to the anodizer, gets processed, and comes back before it can be assembled, crated and shipped. The finish adds a round trip to every batch, and nothing in the shop moves while a batch is out.
So the work had to be batched to keep the tanks full and the floor busy at the same time — sequenced so that what came back was always what the next assembly needed, not what happened to be ready when the truck left.