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.
Who should attend?
William 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