Today’s Guest Blog Author: Kris Chapman is the Vision Lean Manager at Trilogiq USA. Kris has 15 years experience in helping manufacturing facilities implement Lean Manufacturing principles.
Have you ever viewed people or machinery movement as a waste? Movement waste is easier to identify and measure but difficult to resolve due to the complexity of parts and processes in a limited space. Movement wastes time and energy and can affect health and safety through excessive wear and tear on personnel and machinery.
Some key things to look for when identifying movement waste are:
- Watch a process flow. Do and you see excess motion through distance of parts from the operators?
- Are people moving more than three feet within a work cell, reaching over their shoulders, or bending over to pick up material from the floor or low storage areas?
- Have you observed walking or excessive travel of team members?
Many movement wastes are the result of poor layout or space constraints in the work area. When diagnosing movement waste, use a spaghetti diagram to show the movement and follow the individual or tugger/fork truck for a couple of hours.
To resolve movement waste a basic 5S workshop can be completed to remove unnecessary items/steps from the process. With fork truck waste, implementing a train/tugger system can move multiple products while eliminating unnecessary intersecting or redundant travel. Making improvements to prevent movement waste can result in a 50% decrease in team member movement and 25% reduction in tugger/fork truck movement while reducing the amount of steps in your process.