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Basic Stability

The document discusses the concept of stability in production processes, emphasizing the importance of consistent results and the capability to produce reliably. It identifies signals of instability, such as high variation in performance and inconsistent workflows, and outlines objectives for achieving stability, including reducing variability and establishing a foundation for improvement. Strategies and tools for enhancing stability are also mentioned, focusing on waste reduction and standardization.

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7 views10 pages

Basic Stability

The document discusses the concept of stability in production processes, emphasizing the importance of consistent results and the capability to produce reliably. It identifies signals of instability, such as high variation in performance and inconsistent workflows, and outlines objectives for achieving stability, including reducing variability and establishing a foundation for improvement. Strategies and tools for enhancing stability are also mentioned, focusing on waste reduction and standardization.

Uploaded by

Cr
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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Basic Stability

Initial stability
Stability
• Initial condition before applying Lean Tools
• Stability vs Variability
• Stability → Capability
• “Clearing the Clouds”
Level of Stability
• The initial level of stability is generally defined
as the capability to produce consistent results
some minimum percentage of the time.
• This is measured based on the outcome and is
related to producing the same quantity of
products, with the same amount of resource
time (people and equipment), with a high
degree of reliability (the exact level may vary
according to the process and conditions, but a
reasonable rule of thumb is 80 percent or
better).
Signals of instability
•A high degree of variation in performance measures—(pieces
produced or pieces per labor hour).
•Changing the “plan” often when a problem occurs. (relocating
labor or leaving a position vacant when an absence occurs,
moving product to another machine when a breakdown occurs
and stopping work in the middle of an order to change to
another order).
•It is not possible to observe a consistent pattern or method to the
work.
•Batches or piles of work in process (WIP) that are random—
sometimes more, sometimes less.
•Sequential operations that operate independently (island
processes).
•Inconsistent or nonexistent flow.
•Frequent use of the words usually, basically, normally, typically,
generally, most of the time, when describing the operation.
Objectives of Stability
• The primary objective of the stability phase
is to create a basis for consistency so the
“reality” can be seen, and random activities
removed, thus establishing a foundation for
true improvement.
• This includes reducing the variability of the
demand rate (prior to the establishment of
takt time, rate of customer demand) and the
creation of basic daily volume leveling.
Stability: strategies and tools
Look for
Waste

Standard
In Cycle /
Conditions, Moving materials,
Out Cycle
fast return doing paperwork
Losses
to normal
Suggestions

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