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Labor Optimization Services

The following is an outline of a typical labor optimization project:

Base Line Assessment
  • Videotaping of manufacturing operations or on-site pre-determined time study data collection
  • Factory Flow analysis of fork truck drivers and material handling personnel
  • Development of a current state time study for existing operations
  • Identify safety and ergonomic issues for future analysis and recommendations
  • Development of a current state cycle line layout for the manufacturing operations
  • Development of baseline metrics for future comparative analysis to an optimized future state Direct and Indirect Labor plan
Future State Plan Development
  • Rebalancing of manufacturing and assembly content focused on the elimination of non-value added activities which include the following:
    • Defects
    • Overproduction
    • Waiting
    • Not utilizing talent
    • Transportation
    • Inventory excess
    • Motion waste
    • Excess processing
  • Correct any identified ergonomic or safety issues from the baseline assessment
  • Development of a future state cycle line layout which identifies to the optimal Required to Operate (RTO) indirect and direct labor plan
  • Update all process documentation to support the new lean and efficient plan
  • Train operators on their new work assignments
  • Provide hands-on implementation support

Note:

Please refer to our Process Documentation Maintenance Program (PDMP) to support future continuous improvement initiatives and future Quality Audits.

for companies of all sizes and at all stages
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