Dear Joe,
Thanks for sharing your interest in comparing the paybacks of local improvements with the paybacks of investing in the 'big' solutions. I'll offer a way of thinking about some usual cases.
Local improvement with a quick time for approval
I work in a work cell. Throughout the day I need to leave the workcell to use a drill press across the plant. It takes some time to traverse the plant. (Sometimes I have to make the trip twice because the piece needs reworking.) I discover the plant owns extra drill presses. As an individual I see the opportunity to claim one of the excess drill presses for my workcell. My workgroup leader likes the idea so we move to implementation. I spend 1 Hr arranging, moving, and setting up the drill press. The plant is now in the hole the value of 1 hour. The benefit is now the removal of the interruption — stopping, time walking to the drill press, returning, and re-starting. The drilling is the same whether close by or distant, except that the drill press might stay in a 'ready state' for drilling when it is part of a work cell. Immediately, I have the extra time for producing more throughput and I might encounter other side benefits. When graphing this the plant makes the investment of 1 Hr. and begins getting benefits immediately. When using a time scale of a week, you might not see the money spent, let alone using the time scale of a month.
Compare this with the 'big idea' improvement
An engineer and others spend time for week after week studying, collecting data, analyzing, proposing, getting approvals, dealing with well-intended suggestions from somewhat interested others, and finally implementing. (Please don't read that as cynical. It acknowledges the usual drive for a correct solution. I'll say more later.) During that time no new value is accruing. Costs accrue through the time when the proposal is implemented and returns begin. Plotting this would show starting at zero going negative for N months then beginning the climb back to zero. Only the great solutions climb fast enough to show payback in one year. Most "investments" show returns of 15-25% thus taking anywhere from 3-7 years to payback.
In the first case let's say you are getting 3 improvements every 4 days for a group of 50 people (consistent with national averages of good companies getting 4 improvements/person/year). That is not a bad rate, but it still shows thinking attached to the conventional wisdom. What's that wisdom? People can be expected to act in their self-interest rather than for the benefit of the company. (This harkens back to Adam Smith.) However, if you can avoid the approval process, then the rate of improvement can go way up. One group of 45 people I recently worked with 'adopted' just under 500 improvements in their first 7 weeks. That is about 5 or 6 improvements/person/month! Notice I didn't say 'proposed' and 'approved'. They usually did neither. We used three rules to avoid that.
- If the workgroup agrees it will be more value, AND
- If it doesn't require a new cash outlay, AND
- If it can be done on your shift without interrupting production or others, then just do it.
Everything else needs the foreman's approval. I don't recall how much went to the foreman for approval, but they were acted on promptly.
Pursuing 'correct solutions'
In usual situations managers and engineers removed from the factory floor or the operations of a workgroup are responsible for improving the performance of the process. They pursue this work as projects. Workers are just responsible for production. In these cases we often find the detachment of the engineers and managers leads to proposals about improving local productivity rather than the ideal 'objectivity' and optimal solutions we are seeking from these objective people. Anyone who has even the slightest concern for prudence will choose to take time to be sure that what is being changed will do more good than harm. Investigating that is what so often consumes the time on these projects. In the end we get what we get. Some changes are real improvements while others are write-offs.
Now don't get me wrong. I think we should be doing process engineering, making capital investments, and bringing in subject-matter experts. Here's the problem: almost any investment proposal looks good when evaluated against a poor current state. But what if the current state was on a continuing path of operator-directed improvement? What if those improvements were focussed on reducing dependence and variability? What if those improvements resulted in increased throughput? And, what if those improvements were done with little to no delay? Then…what would we be investing in? I bet they would be very different. We might even have fewer projects.
Hope this helped.
Now, for all you folks who want to look at the graphs…you'll just have to wait! It will take me time to create something that shows how profit velocity varies in the two cases.
LPSThe Last Planner System® is a lean approach to planning and delivering projects. It is based on a hierarchy of planning: should, can, will, and did. LPS is not a computer system. It is a set of protocols corresponding with the four above items: pull planning, look-ahead planning, task planning, and daily coordination.
The Last Planner System is a registered trademark of the Lean Construction Institute.
Last Planner SystemThe Last Planner System® is a lean approach to planning and delivering projects. It is based on a hierarchy of planning: should, can, will, and did. LPS is not a computer system. It is a set of protocols corresponding with the four above items: pull planning, look-ahead planning, task planning, and daily coordination.
The Last Planner System is a registered trademark of the Lean Construction Institute.