5 Step Process To Removing Complexities In Manufacturing Processes
April 27, 2011 4 Comments
A good place to begin removing complexities in our manufacturing operations is in our secondary processes. Often there is a clear delineation between a primary manufacturing process and a secondary process. For example, an organization that produces plastic widgets may identify its primary manufacturing process as injection molding, the conversion of plastic into a widget. Processes such as separating, assembly, packaging and finishing are considered its secondary processes.
Since primary or core processes tend to be the processes best understood within our organizations, it seems logical that gaining a better understanding of what is happening after core processing, creates an opportunity to reduce complexity.
When it comes to removing complexities, there are no quick fixes. The concept behind this 5-step process is to gain a better understanding of how we currently produce our products. Working through this process, we find a natural inclination to simplify.
- Create “as is” process maps – Document the whole route the product travels from it’s core/primary process to the next, or secondary processes, following the product through to its finished, shippable state.
- Define processes – Document processing specifications at each secondary process defined in the process map.
- Measure cycle times – Measure each process to understand process time requirements for each process articulated in the process map.
- Evaluate Sequencing – Evaluate each process and determine its fit within the larger system based on cycle time, finishing order and value creation.
- Simplify – Remove non-value added processes by reducing extra processing steps, product travel times and redundancies.
It can be difficult to peel back the many processing layers involved in our manufacturing operations. However, once the manufacturing journey our products travel are stripped down to minimum processing requirements, we can begin to rebuild our processes with a new clarity. This new clarity provides a shift in perspective, creating an opportunity for an intentional, re-focused effort to align our manufacturing processes with strategic business objectives.
Another great article! I think these high level steps will do the trick. At #3 (the measure step) I would suggest one may want to also measure inventory. That is the number of units accumulating at the end of a step prior to the next step in the process. Ideally you would have no inventory between processes (one of the waste elements you are trying to drive out). If you do see inventory there, this is an indication that the line may not be properly balanced. Also, on an otherwise well balanced line, seeing inventory in between processes is a good visual indicator that something may be wrong with a sub process, equipment, parts, labor or some other anomaly.
Hi Jaime, Thanks for your positive feedback! Great point, excess inventory is a good indicator of process imbalance. Step #3 seems like a great place to measure inventory to further understand why build-up is occurring. Thanks for pointing out that these are high level steps, the real effort is rolling up the sleeves and doing the work. Do you think process improvement lends itself to decreased complexity?
Absolutely! I have seen it myself using these high level steps to dig in, identify the issues as you stated and simplify. Sometimes process improvement can be intimidating but with these 5 steps you are given a direction and order of operation in order to simplify. I would recommend anyone new to process improvement to try it out on a simpler process first. I think folks will discover this does not need to be intimidating and with a simplified, more efficient process, they will also find it rewarding both professionally and to the bottom line. Of course, on more challenging processes, I would recommend they bring in some help such as you can provide! Either way, process improvement can be a quick win to faster turn times, improved quality and reduced costs.
Hey Jaime, Great conversation! Thanks so much for contributing your experience and enthusiasm on this subject. I am a bit passionate about the topic myself and enjoy discussing the concepts with others. Thanks again!