In our assembly operations, we have implemented various poka yoke systems to assure our manually assembled product meets our customers expectations. We have implemented productivity rates which were based on a average between three different assembly operators. This system allows some operators to crusie through the assembly with quality product and others to struggle with several defects. Is there a better way to develop productivity rates that anyone knows of?

In the machining portion, productivity rates are simple, operators are expected to obtain 93% of the productivity the machine can produce. Operators are consistant in their throughput and quality.

Please let me know your thoughts.

Thanks

Bob Stevens

Not easy to comment in detail given what is posted.

But then again maybe I'm just understanding the situation.

Are the assembly operations - independant of each other? or interdependant for the end product :confused:

I am currently working on establishing more consistent productivity rates for the assembly lines at my plant. The difficulty that has arisen is a cheap, effective way to communicate the expected Takt time to the operators. We have a clock "ticker" at the end of the line, however most of the operators can't even see this; those that can don't pay it any attention.

What have you done to commuicate the productivity rates to the operators and how have you enforced them?

Also, as a side - what types of successful poka-yokes have you been able to implement. This is of course an ongoing project and I'm always looking for new ideas!

Just a suggestion, but based on the variation you are seeing, either three may not have been the appropraite sample size or the sample you took was not representative of the population of assembly operators.


Finally, check out your learning curves; you might still be early in the adaptation to the changes.

Ben

The process you describe is typical of many assemly operations and it's not worth the time or effort to try and patch them up.

The first thing I would do is to attend a working seminar on lean manufacturing. Then come back to your facility and sart from scratch.