Lean Nation;
This week the tool used in improving the work area was the cycle time takt time bar chart. While we have discussed this tool in an earlier blog, I wanted to highlight a key point. The work ended up being a three person operation. The takt time was 45 seconds and we needed to balance the work to that time. after a trial we were at 22seconds, 61 seconds, and 40 seconds. A heavy amount of electronics was necessary for the second step.
The team immediately decided that the second station was not going to be able to complete the work within the takt time and we should capitalize the third station that would essentially look identical to the second station.
On first glance this looked plausible and perhaps the only option. However, after re-studying the process the team was able to re balance the work without flow stoppages and complete the step in the takt time.
To me, the fundamental question is are we trying to make the work easier, or are we trying to free up wasted manpower? Many teams default to making the work easier. But it is management's responsibility to free up excess manpower to make people available for adding value in another part of the organization.
Making the correct move today saved an FTE, along with an 18% improvement in throughput. Do you have the courage to make the right decision?
Lean Blessings,
Ron
Ron Bercaw
www.breakthroughhorizons.com
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