Lean Nation,
One of the common tools used to see and eliminate waste in a lean environment is time observation. There is no better way to see waste than through direct observation. You can spin work and processes many different ways, but when we go to Gemba, the place where work is done, and observe, waste is seen everywhere.
As a refresher, waste is any activate that takes time, space, or resources, but fails to deliver value directly to a customer. When we watch work being done, we can quickly observe that 95 to 99% of the time, no value is being added.
So what does time observation have to do with direct observation? Great question! Waste can be quantified in time. as we observe we can document in the waste in increments of time. This is extraordinarily helpful because it allows us to determine the cost of non-value added activity. It also allows us to predict the improvement potential when the waste is eliminated. In effect, time observation is a tool used to help both "see" and "eliminate" waste.
Most team members fail to document the time associated with waste. Team members find it easier to use interview techniques and approximate the time or use averages from computer reports. This is actually sloppy work and should be avoided if possible. We want to use direct observation to see the waste and time observation to quantify the waste if at all possible.
When combined with takt time, the data from the time observation can be used to build a loading diagram (see earlier blogs for this topic), that enables the team to calculate staffing levels and create one item flow. This is the key to productivity.
Lean Blessings,
Ron
Ron Bercaw
www.breakthroughhorizons.com
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