How to Boost Production Performance

Stop measuring "productivity" and start measuring flow! Most manufacturing metrics focus on productivity - how busy people and machines are. But being busy doesn't mean you're creating value. In fact, maximizing resource utilization often destroys flow and hurts overall performance. Here are 5 flow metrics that matter more than productivity: 1/ Lead Time ➟ How long does it take for material to move from start to finish? ↳ This is the single most important indicator of your process health. 2/ First-Time Quality ➟ What percentage of work is completed correctly the first time? ↳ Rework is the invisible flow killer in most operations. 3/ WIP Levels ➟ How much material is sitting between process steps? ↳ Lower WIP = faster flow and fewer hidden problems. 4/ Takt Adherence ➟ Are you producing at the rate of customer demand? ↳ Neither too fast nor too slow - just in time. 5/ Response Time ➟ How quickly can you detect and resolve abnormalities? ↳ Fast response prevents minor issues from becoming major disruptions. Implementation steps: Step 1: Make these 5 metrics visible in your area Step 2: Reduce batch sizes to improve flow (even if it seems "less efficient") Step 3: Focus improvement efforts on removing flow barriers, not keeping resources busy Remember: A process at 70% utilization with perfect flow will outperform a 95% utilized process with poor flow every single time! --- Follow me Angad S. for more!

Stop being so traditional Embrace innovation One way is to stop the bad habit of batch production. ___ Batch Production is a manufacturing method items are produced in batches, before moving on to the next step. Some manufacturers think that larger batches are better because they minimize changeovers. But the truth is the exact opposite! excessively long runs cause overproduction. Operators lose focus working on large batches, while equipment drifts out of standards between changeovers. Worse, they making too much of the wrong product and not enough of the right. There are several drawbacks: +defects are tougher to detect +lots of WIP inventory +space management +uneven workflow +over production +long lead times Switching to One-Piece Flow reduces all these issues. Workcells are arranged so that products can flow one at a time through each process step. Changeovers are more frequent, but shorter. Advantages: +low work-in-process inventory +Responsive to customer demand +Quality defects are detected easily +efficient use of space and material handling The choice between batch and one-piece flow is a no brainer. If you want improvements to quality, productivity, and lead time , choose One-Piece Flow.

What’s killing your output? It’s not speed. It’s bad flow. One of my favorite exercises to demonstrate flow involves a simple challenge with ping pong balls. The rules: ✅ Everyone must touch every ball. (they signify an order going through the system) ✅ They must have air time. ✅ They must end where they started. ✅ How many can make it around in one minute? The first round is always chaotic. Balls get dropped (quality errors), people rush (overburden), and the process is inefficient. Then, we run the PDCA (Plan, Do, check, Act) cycle: adjust and try again. What happens? ✅ The fastest person doesn’t matter. The slowest sets the pace. ✅ Hand-offs are where the real losses happen. ✅ No one needs to work frantically: just establish flow. ✅ Expedited “hot” orders (white vs. orange balls) throw everything off. ✅ Moving those who drop balls most to the first step reduces errors. By the third attempt, teams almost always double output and cut defects by a third - or eliminate them entirely. The lesson? ✅ Optimizing one station means nothing if the system doesn’t flow. Most companies I help don't need more machines or more people or even higher OEE, they need better FLOW! 👉 Are you focused on local speed or total system effectiveness? 👉 Where does your team struggle with flow, and what’s one thing you’ve done to improve it? #LeanManufacturing #Flow #PingPong #Focus #Example PS: As a self-proclaimed ping-pong fanatic, I like to break out my Hi-Vis gloves (because all true ping-pong pros wear them, right?) and my undersized paddle-the perfect way to play my kids, keep it competitive, and still sharpen my skills. 👉 Are you a ping-pong pro, or just a casual challenger?