Build it wrong

Have you ever launched a production line only to start making bad parts instantly?

Have you ever launched a production line with a horrible PPM ranking after weeks of meticulous planning?




Product development is complex and demands a process of it’s own to ensure critical elements are considered and implemented. I could –and others have written, volumes on this topic, but today I want to focus and share a tried and true method of bullet-proofing your manufacturing line.


There is actually a trick.

Sure..

• You think you know how to assemble that part.
• You think you’re a good communicator and trainer to teach others how to put it together.
• You think you’ve balanced the line such that every person is done with their assigned tasks in 12 seconds.

You think.

Before you’re finished with designing fixtures and equipment for the production line and certainly well before you even consider a run at rate evaluation, host a ‘build it wrong’ day.

That’s right. Dare your team* to build the part wrong.

HOW TO:
*Collect a diverse group consisting of engineers, managers, team leaders, operators, and maybe even your staff assistant and assign them a ‘station’. At each 'station', provide them all the parts they'd need at that defined ‘station’ along with a few tools both necessary and completely useless, then tell them to put it together.

ie: say: "put this together", and walk away.

That’s right, provide no other instruction, no other words.

In addition, create a special ‘station’ where you have all the parts for the assembly and have someone try to assemble the whole thing by themselves (again without any instruction what so ever).


WHAT YOU’LL DISCOVER:
• Poke Yokes you’ll need to create; both design and process

• Operator instruction noteables

• Product design changes necessary to eliminate possible mis-builds

• Process steps needed

• Special tools required

• Ergonomic changes to the station including fixtures and tools necessary


THE BIGGEST LESSON?

You’ll discover what you don’t yet know.