How to remove bottlenecks in your operations? A simple, 3 Step Approach!
Plus 2 Quotes and 5S Implementation Invitation
1 Article for the Week:
What is a Bottleneck Process?
Cycle time of these processes are more than the Takt Time (Requirement Rate)
These processes determine the output of the line
Improvement in Bottleneck process only can bring increase in the Line’s output
How to reduce the cycle time of Bottleneck Activities? This is a big challenge many of us face after identifying the bottleneck activities. There are 3 ways to do it.
Step 1 - Existing Output: Analyse what’s the current output Vs. the existing cycle time(CT) - Are we producing to the current cycle time? for e.g. If the cycle time is 1 min and available time is 420 min in a shift, we should get 420 pieces. Are we achieving this output? If not, why the output is low? Try to bring the output of the process to the Existing norm (based on the CT)
Step 2 - Once the Existing norm is achieved, Eliminate some of the Non-Value Added Activities in the operation - Can we identify the non-value added activities inside the current CT? Loading, unloading, Slow Tool movements, Frequent Stoppages, Tool indexing times, Operator doing other activities, etc.
Step 3 - Improve the Value Adding Activities - e.g. in a Turning Operation, Can we increase the RPM of the machine? Can we increase the depth of cut? Can we use a better tool and eliminate a rough turning activity(in case there are multiple rough turnings)
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2 Quotes from Ananth:
Flow is built by removing, not adding.
Standard work frees the mind to improve.
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