Whenever we see overtime over 5% an analytical red flag goes up and we start to suspect that there may be too much cost built into the process. Many organizations use overtime to offset peak volume periods.
A consultant spent three hours watching a production line trying to find opportunity. It was a simple quality inspection area where the product flowed in a continuous stream past a number of trained inspectors.
In many operations, back up assignments can be a useful means to even out daily workflow. By providing a “ready backlog” of work that can be pulled if the main task is delayed for whatever reason, a manager can help optimize the productivity of an area.
A lot of productivity is lost due to how work is assigned, or in this case, when it’s not assigned. What we often see is that the manager plays the role of a work collator, someone who creates a backlog of tasks that an employee can draw from. Work is “loaded” as opposed to “assigned.”