The first step in process improvement should always be asking the question, “Do we need to do this process at all?” When many companies start a process improvement initiative, often the first thing they do is either conduct a Kaizen event, or flow chart the process, looking for waste to help target the improvements. This can result in a great deal of time and expense being spent improving something that you shouldn’t even be doing in the first place.
Eliminating the Rework Cell
One of the best examples in industry is the rework cell. Many companies have a special work center at the end of the production line whose sole purpose is to correct problems caused during the production process. I have seen companies spend many hours trying to make that work center more efficient by eliminating waste. The problem is – the whole work center is a waste! It reflects poor process throughout the rest of the production line. The goal should be to eliminate the rework cell rather than improve it.
Focus first on whether the process should be eliminated entirely. Once that decision has been made, then you can focus on improvement.
© 2012 – Rick Pay – All Rights Reserved
