When BMW took over the Mini Brand, they completely rebuilt the assembly line with a massive emphasis on automation. All of the body panels are created in a series of cells that pass from one to the other - on a 67 second rhythm. This perfectly timed dance keeps going all day as robots pass large pieces of metal around each cell and then over the wall to the next cell.
Of course - things go wrong! A robot might malfunction and everything goes into disarray - so at regular intervals around the factory a cell has 15 minutes of material. This allows all of the cells forward of the stock pile to continue manufacturing, while the maintenance engineers spring into action to repair the stricken robot. The point here is that a common rhythm is what makes the factory work so seamlessly.
So we hear you say - 'We are not the Mini Factory'.
Indeed you are not - but do you synchronise your operations? We often look at packing areas full of picked goods and our client is trying to find ways to create a bigger holding area. This is simply not the answer. How many picked goods do your packers need to be sure they won't run out? Half an hours worth? An hour? Can you pace your pick operations so they fill up to an agreed level - then change task? It may not seem obvious - but the best place for your stock is on your shelves - it isn't in anyone's way there. The journey from shelf to despatch bay needs to take the shortest time possible. If your despatch collection comes at 5.00pm - why couldn't your last pick run be at 4.45pm?
Any objections? Sure - the problem is that everyone needs to multi-role. Which brings us back to the Mini Factory - everyone on the production line rotates their tasks between at least three activities across their shift. This has benefits ergonomically and reduces the risk of repetitive strain injury - but it also means that they are really good at each of the tasks that they rotate through. This isn't just cross-training - these operators are highly trained and experienced - they don't hold up the line. Can you do this with your team? Maybe you have two teams - and they are working against each other?
Maybe a trip to the Mini Factory in Oxford for the next team building activity?
