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The Value-Adding "Bang": Understanding Cycle Time (MFGD52D)

Presented By : William A. Levinson , P.E.
(*) Single User Price. For multiple users please call 1-800-223-8720
Pre Recorded Webinar
60 minutes
  •  Thu, December 3, 2015
Event Description
See the sneak peek before you buy!

Gain a Competitive Advantage By Eliminating "Non-Value-Adding" Cycle Time in Production!

A business' ability to deliver what the customer wants, and when the customer wants it, is inversely proportional to lead time: the time between the order's placement and its delivery. Cycle time, the primary contributor to lead time, is the amount of time between the order's release in the factory and its completion. Wasted cycle time hides in plain view in all but the leanest factories.

Masaaki Imai described the basic principle in Gemba Kaizen (1997): "There is far too much muda [waste] between the value-adding moments. We should seek to realize a series of processes in which we can concentrate on each value-adding process- Bang! Bang! Bang!- and eliminate intervening downtime."

Short cycle times allow a business to manufacture to order, while long cycle times require it to manufacture to forecast. Little's Law holds that inventory is directly proportional to cycle time, so large inventories may be the symptom rather than the cause of long cycle times. A manufacturing process adds value only when it transforms the product. This means it adds value only when a tool is in contact with the part; the moment that Masaaki Imai called the value-adding "Bang."

Most (up to 99% or even more) cycle time is non-value-adding. Enormous competitive advantages, including the ability to make to order rather than to forecast, can be gained by removing this non-value-adding cycle time. Elimination of non-value-adding cycle time reduces inventory and its carrying costs proportionally, and may also allow production to order (a sure thing) rather than production to meet uncertain forecasts.

In this session, our expert speaker, William A. Levinson, will show you how to recognize wasted cycle time on sight and effectively eliminate the same from the production line. You will be able to understand the concept of cycle time accounting; the relationship between inventory and cycle time (Little's Law); and how to optimize the various categories of cycle time.

Session Highlights:

  • Know the relationship (Little's Law) between inventory and cycle time.
  • Learn that cycle time falls into five categories: transformation, handling, transportation, inspection, and waiting.
  • How the value-adding "Bang" adds value.
  • Identify most of non-value-adding cycle time components on sight.
  • Understand the concept of cycle time accounting, which breaks down a process' total cycle time into these categories.
  • Learn how the manner in which the work spends its time can be presented in Gantt chart format, which usually shows most of the cycle time to be non-value-adding.
  • Learn some techniques with which to remove non-value-adding cycle time.
  • How single-minute exchange of die (SMED) reduces setup times.
  • Understand how single-unit processing is superior to batch and queue operations, which often waste time waiting (waste by definition) to form transfer and process batches.
  • How conveyor belts and work slides reduce non-value-adding transportation times, and work cells.
  • How pull production control methods ensure that capacity is available, and that work does not have to wait at any workstation (except the constraint operation in the drum-buffer-rope system).
  • Learn how off-shoring adds fixed and substantial cycle time to the process. For ex. A container ship is essentially a floating warehouse full of idle inventory.

Who should attend?

  • Manufacturing professionals
  • Logistics professionals
  • Front-line workers
About Our Speaker(s)

William A. Levinson, Manufacturing Guidelines ExpertWilliam A. Levinson P.E.
William A. Levinson, P.E., is the principal of Levinson Productivity Systems, P.C. He is an ASQ Fellow, Certified Quality Engineer, Quality Auditor, Quality Manager, Reliability Engineer, and Six Sigma Black Belt. He is also the author of several books on quality, productivity, and management, of which the most recent ... More info

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    Event Title: The Value-Adding "Bang": Understanding Cycle Time
    Presenter(s): William A. Levinson , P.E. Protection Status