In many instances, even the most experienced factories fail to recognize obvious efficiency problems. One aspect of Fusion’s productivity continuous improvement consulting is work efficiency analysis. Fusion employs industrial engineers to regularly observe production methods and suggest improvements to work organization.
In one particular garment factory, Fusion consultants realized machine positioning forced employees to remain seated while rotating 90 degrees and extending themselves fully to get the materials needed for their next task. Upon examination, consultants noted movements added four seconds to the completion time for a task. Repeated back strain resulted in worker discomfort and productivity deterioration throughout the course of the day.
When Fusion consultants inquired why the machine was positioned so awkwardly, a supervisor responded, “Because that was the way it had always been.” Apparently the machine was arbitrarily left on the floor, and no one had considered moving it. Fusion consultants repositioned the machine in several different ways and measured standard time for each of the changes. The positioning with the lowest standard time was universally applied to all similar machines in the factory. As a result, the average time required to process materials dropped from 8 seconds to 4 seconds, improving standard time by 50%. The department was able to significantly reduce overtime and produce ahead of schedule.
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