Kaizen: Step Two of the Deming Cycle: Measure Each Operation
If you have not already, you should read the Introduction to Kaizen and the previous article about Standardizing the operations.
Measure Each Operation
While kaizen applies to any kind of improvement, Deming’s primary goal was to increase manufacturing throughput. It would be impossible to say whether this had improved, or by how much, without measuring throughput.
Since kaizen deals with incremental improvements, it is necessary to measure each operation. It may be tempting to try to take overall measurements for throughput. However, measuring each step puts each step under scrutiny.
What needs to be documented?
- Time to initiate a production work order
- Time to bring raw materials from storage to the first machine in the factory
- Time for each machine process
- Time for each manual activity
- Time to deliver finished goods from the last machine in the factory to storage
Time to Initiate a Production Work Order
Whether this is a manual step or an automated one, determine how long it takes to create a production work order. Does it start with the customer’s order, or from an out-of-stock condition in a warehouse?
Break down the manual processes to determine whether anything delays this process.
It is also worthwhile to learn whether the scheduler also checks the inventory of raw materials. There is little point in beginning a work process, only to stop it to procure materials.
Time to Bring Raw Materials for Processing
How long does it take to move raw materials from a warehouse to the first machine in the factory? If materials are delivered directly from a truck to the factory, the only time spent is inside the facility itself.
For all that are relevant to your operation, include the time to:
- Deliver a paper work order
- Assign and actually make a forklift (or other transportation) available
- Move material inside the warehouse
- Move material from the warehouse to the factory
- Move material within the factory to the first machine
Time for Each Machine Process
How long does it take for each mechanized step? Another way to answer this question is to determine the machine’s actual throughput per hour or per 1,000 items.
For example, one machine might include the following steps, so determine the time for each:
- Setup: change the drill bit
- Setup: change the jig
- Setup: perform a “cursory” maintenance check: lubricant levels; tighten bolts; check filters
- Place the material into the jig (or “load the machine”)
- Drill the hole(s)
- Move the work-in-process to the output area (or “unload the machine”)
- Are there periodic time-outs for maintenance checks or to move incoming or outbound materials?
- Are there automated quality tests anywhere in the machine cycle?
Time for Each Manual Activity
How long does it take for each manual activity?
Some manual steps that take time are:
- Fetching incoming materials or delivering outbound materials
- Fetching maintenance materials, such as lubricants, and returning them to storage areas
- Performing manual quality tests
- Affixing labels
- Writing logs, signing documents, or writing up maintenance requests
Time to Deliver Finished Goods to the Warehouse
How long does it take to move finished goods from the factory to a warehouse? If goods are shipped directly from the factory onto a truck for shipment to customers, this step does not occur.
For all that are relevant to your operation, include the time to:
- Assign and actually make a forklift (or other transportation) available
- Move material within the factory from the last machine to the shipping dock
- Deliver any paperwork
- Move material from the factory to the warehouse
- Move material inside the warehouse
After Measuring: Evaluate
This documentation provides valuable insight into the current, or recently improved, manufacturing process. It provides the benchmark against which the next changes can be measured.
Please continue to the next article describing kaizen’s Deming cycle.
Oskar Olofsson, 2011
Kaizen
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I am a Swedish-based Lean consultant, and the owner of the World-Class-Manufacturing.com web site.
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