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Round 1 Debrief: Operational Efficiency and Role Modification

In this Round 1 debrief, we discuss key insights into our operations focusing on optimizing cycle times across various workstations. We target a 30-second cycle time balance, addressing each operation's needs: OP1 requires a jig for kitting and steps 1-3, OP2 manages steps 4-6, OP3 needs a template with steps 7-9 and stamping, while OP4 focuses on oven readiness. Additionally, we propose modifications to streamline our workflow by eliminating the roles of production scheduler, kitter, inspector, and reworker to enhance efficiency.

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Round 1 Debrief: Operational Efficiency and Role Modification

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Presentation Transcript

  1. Round 1 Debrief - pm Balance cycle time between operations (target 30 sec) OP1 kitting + steps 1-3  need jig OP2 steps 4-6 OP3 steps 7-9 + stamp  need template (limits) OP4 oven Modify roles – eliminate production scheduler, kitter, inspector, reworker Rearrange tables – one table per color; rework next to inspector and ovens Alter oven batch size (try size of 2) Use kanban cards to pull work through the factory  make kanban spots Quality at the source (make jigs) Use water striders (displaced workers) Point of use storage
  2. Round 2 Debrief - pm Pace was much more comfortable OP2 is the bottleneck  shift some work to OP1 Goal is schedule the pacemaker  shipping in this case Could deliver raw material more frequently  reducing inventory  Consider vendor managed inventory (Boeing) Oven turned out not to be bottleneck Green oven ran larger batches White oven ran smaller batches Consider doing more inspection at OP1 & OP2  haunch (but we still need to determine exactly what to measure) Ideally kanban should communicate quality requirements, not just presence of product
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