This book explains how to measure the performance of operators quickly and simply, how to identify the most efficient operators, and how to monitor their improvement over time. The method described can be automated very easily, thereby requiring no labor consumption. The approach is grounded in one of the basic laws of factory physics: mastery of variability. The method presented here has been applied with success for years in automotive industry. It is a tool that should be used in the broader framework of Standardized Work deployment.
A strange day in a new plant: the "beheaded chicken"
The hidden cost of human variability
Operator variability and performance
How do I measure operators’ performance?
The Mode Ratio
A-rank, B-rank, C-rank and D-rank operators
The hidden treasure
Initial Operator Performance Mapping (OPM)
Standardized work deployment steps
Epilogue: the quest for mode 80