Step one is to understand and be able to identify the 7 Wastes in the process being studied. I can provide this at your site.

1. Observe the line operation for a full shift and document each task that each operator performs. This may be 3-8 tasks.
2. Observe again and document how many minutes are spent during the shift on each task. Identify any tasks that are not adding value such as waiting or searching. You may be surprised to learn that some workers seem busy all shift but are adding value less than 30% of the time they are being paid.
3. List one task as “waiting” – it might be big!
4. Calculate total minutes available per shift on the line. Subtract out breaks & lunches from the 8 hours – for example 480-30-15-15 = 420 minutes spent on the line.
5. Enter this on an Excel spreadsheet. Build a vertical bar chart with each operator on the team as their own bar. The Y axis is the minutes taken for each task stacked on top of each other. The X axis is the position name -mechanic, labeler, packer, inspector, etc.
6. Do this for each operator

To over simplify:  The chart may show that operator 1’s tasks add to 380 minutes, operator 2’s 290 minutes, operator 3’s 200 minutes, operator 4’s 180 minutes.  You give operator 4’s tasks to operator 3 and redeploy operator 4 to where they are needed more. In this case you have a 25% reduction. Of course, cases vary.

What are the savings worth of say 10% in each of your line teams? If you are interested in having me do this at your site: Contact Stephen at RapidLeanCoach@gmail.com or https://www.RapidLeanCoach.com/contact