How do you measure and improve your cycle time and throughput?

👨💼📈🏭Lean manufacturing techniques emphasize continuous improvement principles to eliminate waste, improve efficiency, and deliver value to customers. When it comes to improving production process performance, measuring and enhancing cycle time and throughput are crucial. Cycle time refers to the average time it takes to complete one unit of output from start to finish, and it measures the speed of your production process and your ability to meet customer demand. A lower cycle time can help you deliver faster and reduce inventory costs, which is essential for businesses that want to stay competitive in today's fast-paced market.

Utilizo abordagens como o Lean Six Sigma para identificar e eliminar desperdícios, garantindo eficiência. Ao empregar métodos estatísticos, como o controle estatístico de processos (SPC), consigo monitorar a variabilidade e garantir consistência. A introdução de tecnologias como automação e a análise preditiva também desempenha um papel crucial na redução de tempos de ciclo. Promovo uma cultura de melhoria contínua, incentivando a participação da equipe por meio de programas de treinamento e reconhecimento. A mensuração constante por meio de indicadores-chave de desempenho (KPIs) assegura que as mudanças implementadas resultem em ganhos tangíveis.

One thing I have found helpful in the improvement of cycle time is process standardization. -Understanding the key differences between Standard work document and Standard Operating Procedures. -Establishment of Standard work helps eliminates much human judged, increase ability to automate and consequently improve cycle time.

Improving cycle time and throughput is a vital aspect of continuous improvement in operations. Here's my strategy: - Start by benchmarking current cycle times and throughput. - Identify and analyze process bottlenecks to find improvement areas. - Apply lean methodologies like 5S and Kaizen to streamline processes. - Invest in technology for automation and process acceleration. - Train the team in both processes and improvement techniques for effective implementation. - Regularly review and adjust processes based on performance data. - Set realistic goals for consistent long-term improvement. Effectively measuring and enhancing cycle time and throughput involves a systematic approach of analysis, implementation and continuous refinement.

Bringing this lens over to IT, the cycle time can have varying definitions. From a Tech Support perspective cycle time would be the equivalent to resolution time. The duration between a ticket being opened, and it being fulfilled. In Development, you're looking at the duration between demand and delivery, or also known as the burn down rate. What traditional IT metrics sometimes fail to measure is touch-time (TT) versus non-touch time (NTT). It's critical to have your ITSM platform configured to track TT & NTT. NTT is any time the ticket is awaiting the business or an outside factor. By focussing improvement efforts on TT, you can achieve greater throughput, but you can also educate your customers on their NTT components.

🔆 Throughput is a critical performance indicator for businesses, reflecting their capacity to meet customer demand and generate revenue. By optimizing throughput, organizations can maximize resource utilization, minimize idle time, and enhance overall productivity. Increasing throughput often involves improving process efficiency, reducing cycle times, and eliminating bottlenecks in production workflows. Moreover, monitoring throughput enables businesses to make informed decisions about resource allocation, production scheduling, and investment in capacity expansion. Ultimately, a focus on throughput facilitates business growth, profitability, and competitiveness in the marketplace.

🔎📈 In the context of lean manufacturing, throughput is a critical performance indicator that measures the effectiveness and efficiency of your production process. By calculating the number of units of output your process can generate in a specific time period, you can evaluate how well you are utilizing your resources, such as machines, labor, and materials, and identify opportunities for improvement. For example, if you can increase your throughput by reducing changeover times, improving equipment reliability, or optimizing batch sizes, you can increase your capacity, reduce your costs, and satisfy your customer demand. Therefore, tracking and improving your throughput is essential to lean manufacturing and continuous improvement.

Things I have found helpful -Improve uptime of processes by: ***Simplification of tasks through Standard work ***Improvement of OEE (overall equipment efficiency) through quality by design and quality programs, improve machine availability through TPM(Total Productive Maintenance) ***Reduction of changeover time by implementing SMED (Single-minute exchange of die) method ***

Choosing the most appropriate method for your specific process and goals is important. Consider the complexity of your process, the accuracy and precision required, and the availability of resources and tools. You can also consult with experts in your industry or field to identify best practices and benchmarks. When measuring, be consistent and thorough in collecting and recording data, and avoid any biases or errors. Finally, use your measurements' results to identify improvement areas, set targets and goals, and track your progress over time. With the right measurement techniques and continuous improvement mindset, you can optimize your production process and deliver value to your customers.📊👨💼💡

💠 Measuring cycle time and throughput requires a systematic approach tailored to your specific process. Utilizing tools like time-motion studies, Value Stream Mapping (VSM), or process flow analysis can offer deeper insights into the efficiency and performance of your operations. Additionally, implementing digital solutions such as Manufacturing Execution Systems (MES) or Business Process Management (BPM) software can automate data collection and analysis, providing real-time visibility into cycle times and throughput. Continuous monitoring and periodic reviews are essential to identify opportunities for optimization and ensure sustained improvements in productivity and efficiency.

To measure cycle time and throughput, you need to identify the start and end points of your process or task, collect data on how long each unit or output takes to complete, and calculate the average cycle time and the total throughput. You can use tools such as flowcharts, value stream maps, or kanban boards to visualize your process or task and track the cycle time and throughput. Measuring cycle time and throughput can help you identify bottlenecks, waste, and inefficiencies in your process or task, and implement improvements to increase quality, speed, and customer satisfaction.

🔧💡 Lean manufacturing techniques can help you optimize your cycle time and throughput. First, identify waste areas in your process, such as overproduction or defects, and remove them. Next, focus on optimizing flow by eliminating bottlenecks and variations. Lastly, implement a pull system to align production with customer demand and reduce excess inventory. Implementing these strategies can streamline your process, reduce costs, and increase efficiency. Remember to continually measure your cycle time and throughput to track your progress and make further improvements.

The difference between ideal cycle time and practical cycle time is very crucial. (example = 30 hours) This difference of 30 hrs can be mapped to all defects/causes contributing to the increased cycle time using FMEA and Fishbone diagram. Occurrence of each defect and time spent to repair it will give us the defects contributing the most to this increased cycle time. RCA can be conducted post that to eradicate these defects.

The idea of running without bottlenecks is unrealistic. While we all like to think we balance our production lines, by definition there is a bottleneck that should be addressed, and every resource should be used to address it. Any improvement in the bottleneck is valued at the cost of the entire line for that increment of improvement. The book “The Goal” by Eli Goldratt does a great job of explaining this principle. We require all new managers to read it as primer.

📌 Enhancing cycle time and throughput entails implementing lean manufacturing principles to streamline operations. Techniques like value stream mapping and 5S methodology pinpoint inefficiencies, while automation and technology integration boost efficiency. Cross-training employees and fostering collaboration drive improvements. Regular monitoring and feedback ensure sustained progress. By focusing on waste reduction, process optimization, and skill development, organizations can significantly enhance cycle time and throughput, ultimately increasing productivity and customer satisfaction.

One way to improve cycle time & throughput within continuous improvement is to apply the lean principles of value, value stream, flow, pull, and perfection. Value is what the customer is willing to pay for, and value stream is the sequence of activities that deliver value. Flow is the smooth and uninterrupted movement of work from one activity to another, without waiting on rework. Pull is the principle of producing only what is needed by the customer, when it is needed, and in the right quantity. Perfection is the pursuit of excellence and continuous learning. By applying these principles, a process can be optimized to eliminate waste, such as overproduction, inventory, motion, defects, over-processing, waiting, and transportation.

🔍📈👀 To ensure that your improvements in cycle time and throughput are sustained, it is important to have a systematic approach to monitoring and evaluation. Begin by establishing measurable goals and objectives and regularly reviewing progress against these targets. Collect data on the key metrics, such as cycle time and throughput, and analyze the data to identify trends and areas for improvement. Use visual management techniques, such as dashboards and scorecards, to track performance and make it easier to spot anomalies. Encourage employee involvement by seeking feedback on improvements and implementing suggestions. Finally, communicate the results and celebrate the successes to sustain motivation and engagement.

A process can be monitored and measured using key performance indicators (KPIs), such as cycle time, throughput, defect rate, customer feedback, etc. These KPIs can be used to identify gaps and opportunities for improvement, and to implement changes using the plan-do-check-act (PDCA) cycle or other problem-solving tools. By following this cycle of continuous improvement, a process can achieve higher levels of efficiency and effectiveness.

Ways I have found helpful in sustaining improvements are; -Treating every problem as an opportunity and not blaming people. -Employee empowerment to become owners of the processes by identifying and reporting problems where found as they see. -waste identification program as a foundation for both management and other employees. -Reward good behaviors and coach those not meeting expectations. -Celebrate small progressive steps and victories. -Improve processes instead of blaming people because good processes will eliminate bad will eliminate bad behaviors.