This process looks fine - until you do the math

Here's a classic factory issue.

- REY ELBO

(SOURCE: Rey Elbo, "Total Quality by Maximization", p. 88 2016 edition)

The current work process (see illustration below) appears normal to many people, but not to Kaizen and Lean Thinkers. You may ask—could this be solved by Six Sigma black belters?Short answer: Yes. Except that this is better solved by Kaizen and Lean Thinkers (KLTs) without heavy statistical analysis because it’s a commonsense problem.

The process looks perfectly respectable. There are three workers, two machines, and a conveyor belt ~a sign that some factory managers are unmindful of their problems.

If you squint hard enough, you might understand why KLTs have a cruel habit of asking questions like: Is there a better way? Why does a single work piece need to be handled by three different workers? Why does it have to travel several meters between two machines that clearly belong together? And why are we paying rent so a work piece can enjoy a leisurely conveyor ride?

Welcome to the fascinating world of invisible wastes — where activity is mistaken for progress. Let’s do a recap.

Worker A loads a work piece into Machine 1. The processed part exits near Worker B, who picks and places it onto a conveyor belt.

The conveyor faithfully transports the part to Worker C, who finally loads it into Machine 2.