Reducing Variations In Assembly And Packaging Processes – A 3-Step Guide
January 9, 2012 4 Comments
Assembly and packaging processes, sometimes referred to as secondary processes, can be difficult to define, measure, analyze and control. Labor-intensive, secondary processes performed by us humans seem to present the most challenges. The unpredictable nature of human performance can be overwhelming, making it seem impossible to feel confident about the accuracy and consistency of our processing methods.
Uncertainty feels risky and is frustrating to deal with. Blaming the people performing the process seems like an appropriate behavior, however, I have found it is more productive to take a curious approach and understand what drives this unpredictability.
So the then the question becomes how. What course of action can be taken to understand what causes variation and unpredictable outcomes? Broadly speaking, we need to look at the system inputs, such as, process, people and tools. The first input to become curious about is the process. Some questions to consider include:
- Is the process defined?
- Are process tasks defined?
- Are tasks and sub-process measurable in terms of quality and quantity?
Once the process is defined and measurable, move to a review of the tools needed to perform the tasks and sub-processes. Some questions to consider about tools include:
- Are the tools widely available
- What training is available for tool use
- How are tools calibrated and maintained to ensure consistent performance.
Finally, we can review what specific skill sets are needed to use the tools and perform processes. Some questions to ask about skill sets include:
- What types of motor skills are needed, fine, gross or a combination of both?
- Are hand strength and dexterity needed?
- Are detailed math skills needed for measuring and counting?
After negotiating this adventure in curiosity, we can start inserting humans into a well designed, measurable process where variations can be analyzed and controlled.
While this 3-step guide may seem time consuming, the benefit of doing this work is an ability to create fantastic training programs to further our goal to offer great products to our customers.
Speaking of great training programs, check out this sample video, highlighting ASAP’s performance training video production capabilities. We have also included the corresponding Shrink Wrap Quality Training Test.
Good to skip the blame game and focus on solutions. And to be prepared ahead of time is doubly helpful. I liked the video. I wonder how many first time employees are completely baffled by the vocabulary and processes of the production work floor?
Hi Colleen, thanks for reading my blog post and viewing our video. I am happy to hear you like the video. I agree, I think we often expect new employees to know what we know, and then get upset with them for not knowing. Although this approach is not rational, my sense is that we all have been guilty of this behavior. It can be difficult to put ourselves in the “new employee” mind set when creating training and orientation programs. Thanks again for you thoughtful comment!
Great job! I absolutely agree – employees don’t come to work planning to do a mediocre job – mediocre outcomes result from lack of or poor training and failure to communicate end quality needed. Better training comes from good process, it’s too easy to forget a step if you anecdotally explain job instructions.
Hi Summer, Happy New Year! I hope you are well. Thank you for reading my blog post and for your generous comment. I believe there are great rewards when we choose to take resonsibilitiy for our business processes, whether we engage our internal resources or get help through alternative sources. Were you able to watch the video? I wonder what you thought about the quality of content and filming.
Thanks again Summer, wishing you the best in 2012!