When manufacturers look to improve their production throughput, it involves analyzing cycle times and eliminating lost time. Cycle time analysis in a given production work cell involves establishing a trial or initial time, documenting idle time, and then eliminating that idle time completely. So, what are cycle times and why is it so important when in production cell management?
Lower Cycle Times Increase Production & Eliminate Lost Time
Lost time in manufacturing costs money. It’s that simple. Identifying that lost time and eliminating its root causes, not only improves production throughput, but also reduces costs and improves efficiency. However, every company needs a starting point and when it comes to cycle time analysis. This includes analyzing a product cell’s current productivity and efficiency.
Understand Total and Individual Cycle Times
There are cycle times for the finished product and there are cycle times associated with each operation to make that product. Reducing those times at every stage will reduce the overall time. However, addressing one production cell, and not the other, will only create a backlog in the process. Therefore, consider it as a closed loop process where the entire chain must be analyzed and improved. How is this done?
1. Don’t Rely on MRP Itself, See for Yourself! Many companies assume their MRP (Materials Resource Planning) software package will manage the cycle times in production. Unfortunately, it only shows what those times are, not how to improve them – and that’s a big difference! Success depends upon analyzing that time in person.
2. Understand The Process of Cycle Times: Every work operation has a cycle time with a beginning and an end. This involves tracking time at the point the work begins, and stopping that time once it finishes. It’s essential to define the beginning and end of the work operation in order to take the proper time.
3. Assess Existing Cycle Times In Given Production Cell: This involves standing there and capturing the initial cycle times, flaws, lost time and all. Don’t interfere with this initial time. Capturing high cycle times is essential in capturing lost time, so be sure to not interfere no matter how bad the initial times are.
4. Track Lost & Idle Times: Lost time in manufacturing is easy to recognize. It could be caused by an operator lacking proper work instructions, machine downtime, poor assembly drawings, lack of proper tools or just constant interruptions. The point is, lost and idle time will be easy to spot in the initial times. The next step is to eliminate the causes of lost time.
5. Start New Times After Eliminating Root Causes: All those issues from those initial times will be addressed, and a new set of cycle times will be taken. Improvements may be gradual, but it will become abundantly clear just how costly those delays were. Gradually, cycle times will improve and lost time will be eliminated.
Once the new times have been established, it’s then much easier to track any deviations from those times through a company’s MRP system. The importance is evaluating those initial production times in person, eliminating lost and idle time, and then tracking any deviation from those times afterward. The best companies constantly revisit their cycle times, looking for new and improved ways to increase production throughput.
Ian Johnson - I currently run a business blog called www.driveyoursuccess.com. I have over 15 years consulting experience in production cell management, ...
