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PDCA 1

Step : In order to transform the process of indpacking into a one flow we used division of labbroke the entire process into a two operator

Expectation: We expected the new process to e

the decision making time as the second operatoof box decision making.

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What actually happened: The throughput in thprocess did not make much difference becausalthough the decision making time was reducebenefits reaped were taken away by the time due to improper flow caused by unbalanced dof labor.

Learning: We all observed that there was a lacflow and we thus learnt that its very importanbalance the division of labor for the flow to besmooth and consistent.

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PDCA2

Step: The learning from the previous PDCA helpecreate a proper flow by using balanced division olabor. We could achieve this by involving threeoperators in a work station.

Expectation: We expected a smoother flow ascompared to step 1 and thus better throughput.

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What actually happened: Though the throughpa little better, there were abrupt discontinuitie

flow because the second operator stood up as bottleneck to the process thus creating idle timothers.

Learning: After analyzing this experiment we cawith a very important observation that intermebuffer is necessary.

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PDCA3

Step: Based on the experience of our previousexperiments, we designed a process to create apiece flow with three operators along withintermediate buffer between each operator.

Expectations: This experiment was predicted toeliminate the bottlenecks thus giving us reducetime.

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What actually happened: The throughputconsiderably improved and the process was goin

smooth and fine but we observed that the smalboxes of bacon which are very easy to handle direquire multiple handling.

Learning: We learnt it is essential that we eliminthe packaging of these small boxes from the entflow process.

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PDCA4

Step: The third experiment gave us the insight to

out a mix of the regular one operator and the nethree operator processes so that we reap the beof both.

Expectations: The mix should highly improve thethroughput as smaller boxes and the bigger boxebeing dealt separately based on what suits the bbest.

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Current condition , Target condition Challenge

Current Condition: Takt of 17 seconds ( non-peak) wpackers

Target Condition: Takt of 13 seconds with 12 packers

Challenge Condition: Takt of 8 seconds with 16 packe

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Obstacles that are being addressed

Time wastage due to - Box decision making

- Getting rid of the trays

- Resting between orders

- Individual movements

Variability in type of Boxes

Variability in demand

Variability in the experience of the workers.