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Measuring productivity/efficiency

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  • #52116

    Roy Whitaker
    Member

    We have established our baseline information for productivity and are interested in installing productivity boards.  These boards would have the takt time and cycle time within the calculations.  We wish to measure against current production rates versus the takt time to determine the real time efficiency.  We would like to be able to generate reports from this system that identifies individuals that are producing less than efficient quantities. 
    Anyone know of a system that will produce this and a mechanism that we can use to count the items produced without allowing the employee to skew these rates.  I want to display the efficiency and goal information on the board continuously.

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    #182831

    Kluttz
    Member

    Depends on your process. 
    What are you producing?  What is your level of automation?  What is your inspection/test process (because we really don’t want to be incentivizing productive defect manufacturing)?  What’s your budget? etc etc.
    Depending on your process, your solution may be manual tick sheets displayed daily OR FactoryTalk coupled with automated visual sorting and inspection. 
    Side note: if your management team doesn’t already know how productive their employees are, Visual Factory isnt your biggest problem.

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    #182836

    Roy Whitaker
    Member

    We are producing soda and beverage drawers.  We have used the manual process that you describe but that leads to the ability to pencil whip the outcome.  We have some triggers in place to determine if we are on time or not but we have so much WIP in play that it really does not become a problem until we reduce the WIP which is what I am doing.  We are looking for a visual management system that will update and calculate without any kind of manual input of data. 
    Our automation is nil with a limited budget of around 1,000 or less, preferably less given the current economic environment.  The inspection process we currently utilize is when we retrieve the completed beverage drawer and we have visuals in place identifying the correct specification.  They examine the drawer prior to placing it in the carts.

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    #182839

    Kluttz
    Member

    Ok, so we’re pretty much ultra-low budget here.  But we can work with that.
    Slight disclaimer –  I’m not convinced that productivity tracking is a solution to your problem here, but I’m just going to address it as it is. 
    You can’t track it automatically as an output from the operator for less than a thousand dollars (and I doubt youd want to anyhow – you’d only be incentivizing your people to sacrifice quality for the sake of quantity) 
    Get unique color-coded or number stickers for each of your assemblers.  When the complete a drawer. they put the sticker in an inconspicuous place (or anywhere if theyre easily removeable).  The drawer is passed to an inspector who verifies that it meets specifications.  If it does, they enter that color into a tracking form that in turn is displayed on a large monitor mounted over the line.  Something like this;
    Op1(red) – 8 units     Op2(blue) – 14 units    Op3(green) – 6 units  etc
    Your only cost would be for the monitor and stickers.  The time it adds to the process is minimal.  The operators won’t be able to manipulate the results (unless theyre sleeping with the inspectors).  You can post results as pure quantity or as a % of daily goal and roll total operator productivity vs required takt. 
    Of course, without seeing your process, I could be completely on the wrong page.  I reserve the right to look like an idiot.
     
     

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    #182840

    Mikel
    Member

    Union,
    You are much to kind. I suspect Roy and his company could not define takt time and it usefulness. Looks like some kind of labor standard from the description and its going to be used as a punative measure.

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    #182841

    Sloan
    Participant

    Stan,
    Are you suggesting that this is a diabolical motivation ploy on behalf of Roy’s company?
     

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    #182843

    Kluttz
    Member

    Yeah you know, I almost went there.  I actually debated back and forth for a while on how to approach it (which is why I went with the disclaimer). 
    But we just had that thread where we were berated for being sarcastic, condescending, etc and I tried to take that message to heart.  So I ended up giving him the benefit of the doubt.  The whole kindler, gentler thing. 
    Regardless, he’s got bigger problems than the productivity measurement. 

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    #182844

    Roy Whitaker
    Member

    All,
    Many thanks for your attempts at humor, but much to your dismay I fully understand takt time and cycle time.  We currently rely on a manual method of capturing this and it is far too easy for them to manipulate this data.  What we are searching for is a productivity board that will measure their efficiency, target, and current rate of our operators.  Now if this is seen as a motivational tool then absolutely I need to motivate my people to ensure that they are working at the efficiency that is needed therefore I do not need to employ more people than what is needed.  As a leader I need to be able to see this information and ensure that our production line is operating correctly therefore allowing my team to become proactive and address issues rather than reactive and address the same issues but way too late in the process. 

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    #182845

    Mikel
    Member

    I don’t believe you understand takt time. Please explain it to us.I know this will probably offend, but if you talk this through, you may
    understand what to do.As a leader, you should be able to look out across the production
    area and know, you don’t need some dumb report.

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    #182847

    Kluttz
    Member

    Yeah, now we have a problem. 
    I “get” your perspective.  Totally understand where you’re coming from.
    But this project is doomed to total catastrophic failure.  Period.  With absolute certainty.  When it fails, please come back here and we can discuss why it failed.
    Quick question – If your people are willing to falsify data, then how exactly do you think a display is going to motivate them? 

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    #182848

    Roy Whitaker
    Member

    takt is the pace of production that it takes to meet the customer’s demand.  It can be calculated by identifying the total amount of time available divided by the customer demand.  The total time available is calculated by the number of hours of an employee minus breaks, lunch, set up time, briefings etc.  The customer demand is given to you by your customer. 
    Cycle time is the time that it takes to produce one complete unit in seconds.  We use cycle time divided by takt time to indicate how many employees are needed to complete the task.
    Our setup is not a normal factory floor.  I am looking for a productivity board that shows the current rate and whether it is meeting the demand.  If not we can then move our resources around or identify the problem within the production line and correct.

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    #183303

    cxg174
    Participant

    This is sad. A dehumanizing attempt to “motivate” people that will make them hate and despise you, and will result in possible sabotage or worse, certainly loss of employees, and ultimately a reduction of productivity from loss of morale.
     
     

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