Throughput recovered on a constrained line
Volume commitments were being met with structural overtime, and a capital request was on the table to add a second line.
The real constraintA single changeover step, unmeasured, absorbing capacity that nobody had attributed to it.
The work
- Value stream mapped end to end with observed, not reported, cycle times
- Changeover broken into internal and external work and re-sequenced
- Standard work rebuilt with the operators who run it
- Control chart placed at the line and tied to the existing daily review
What gets measured
- Changeover timeDown
Baselined by observation, re-measured after standard work
- Structural overtimeDown
Tracked as hours, translated at loaded rate
- Capacity releasedUp
Compared against the deferred capital request
SustainmentLine lead owns the chart, response actions are documented, and the measure is reviewed in a meeting that already existed.
