Question

Read the Case: Value Stream Mapping and answer the following questions:

a. Eliminating the queue of work dramatically quickens the time it takes a part to flow through the system. What are the disadvantages of removing those queues?

b. How do you think the machine operators would react to the change?

c. What would you do to ensure that the operators were kept busy?

Answer 1

1. Eliminating the queue of work dramatically quickens the time it takes a part to flow through the system. What are the disadvantages of removing those queues?

Eliminating the queue will decrease the amount of time that it takes parts to flow through the system but this change, as with every decision, could come at a cost or disadvantage. Some of those possible disadvantages are:

            a. As you increase production volume to produce more in less time, it could have the opposite effect of a decrease in quality. It is important to identify what the probable unintended consequences of this decision might be and put in place measure to mitigate that risk to quality as you increase quantity. If a quality assurance team is already in place it could mean increasing the size of the quality assurance team to keep up with the higher demand associated with the higher production volume.

            b. The combining of machines 1 & 2 into a cell could mean that upon a machine breakdown, the effects of this would have a greater impact on the production processes possibly shutting down the entire operation completely until the issues are resolved.

            c. Equipment breakdowns of any significant amount of time could have rippling effects throughout the entire supply chain. This rippling effect could reach outside of the plant itself, possibly even effecting suppliers or other partners along the chain as it could result in a back log in the system.

2. How do you think the machine operators would react to the change?

Most people struggle to deal with changes unless the changes result in simplifying the process thus making the job of the line workers somewhat easier or more efficient. The changes could mean that workers may have to undergo possible re-training or the development of new skills or to build on existing skills. How it effects the workers depends on how it impacts their work. If the process is streamlined then it could increase the morale and motivation of the workers as they are capable of accomplishing more in less time. Sometimes the changes could result in reduction of personnel needed for the process due to the implementation of robotics thus displacing some workers.

3. What would you do to ensure that the operators were kept busy?

As is depicted in exhibit 12.17, I would combine machines 1 & 2 in order to avoid long delays and prevent inventory pile up. Combining the two machines could mean that additional training is needed and will result in optimal utilization of the operator's time and resources. Utilizing lean concepts will make sure that operators remain engaged and avoid pile up inventory.