What is actually happening in the process you are observing

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Reference no: EM133412509

Case Study: Observe a running process, preferably a manufacturing related process. It may be a process you observe in person, such as a fast-food kitchen or oil-change/car service or on-going road construction process that can be observed safely.

You may consider a service process as well - a supermarket check-out line, a warehouse operation, etc. If you are currently working, and have permission, try this exercise at your workplace.

Alternatively, you may find a video of a manufacturing process. There are several under the search term "how its made" which provide process details. Try to find one that shows a process running over several cycles so you can observe how the operator loads/unloads, retrieves tooling, performs inspection, makes adjustments, waits for part, etc.

Questions: Watch the process run, and look for a minimum of 4 specific wastes.

Name the process. Be as specific as possible - rather than "road construction" describe the specific process you are observing such as "pot-hole repair"
Describe the "value add" goal for the process. In other words, what is the customer or employer "paying for." For example "filling in an existing pot-hole to make the road-way level." Everything else (travel to site, unloading tools, searching for a shovel) should be considered non-value added activity.
Describe the basic process steps. Provide a break-down of what is actually happening in the process you are observing.
Identify 4 examples of waste you observe in the process. Name the type of waste (any of DOWNTIME). Describe each waste in clear detail. What are you seeing, how is it a waste, what is being wasted.
Try to quantify the waste - how much time is spent retrieving tooling, what qty is scrapped or what time is spent reworking, etc.
Make a reasonable and specific suggestion of how each waste could be reduced or eliminated. Be as specific as possible. Try not to add cost to the process - for example, adding another person is not generally an acceptable solution. Consider relocating items, improving procedures, introducing Poke Yoke, 5S, etc.

Reference no: EM133412509

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