We hear it all the time from manufacturers large and small: “The job standards are wrong.” Being the nerds that we are, we ask the question “why?” and “what can we do about it?”
Most often job standards are specific elements like cycle time, how long it takes to make one part and setup time, or how long it takes to prepare a machine to run a job. When these are incorrect, they lead to scheduling issues, delivery issues, and job pricing issues on top of operator frustration when incorrect standards are not updated. Operators get discouraged when production schedules become unrealistic and on-time delivery becomes a struggle.
What’s the lifecycle of a job standard? First, you need to create these standards, then confirm that they are true. Most often an engineering team will create these based on the features and geometry of the part. This often helps manufacturers get a sense of what the cost would be to create this part by the time needed to create one. The challenge here is that these standards are usually created from CAD/CAM files and an understanding of the tool paths needed to make the part. For a part that’s never been made, this is typically a theoretical calculation. Out on the manufacturing floor, the theory meets reality, and standards often require adjustment or fine-tuning.
When we speak with operators, it’s always important for them to see how they are performing relative to job standards and production schedules. This is sometimes because the operators have performance incentives on a parts-per-hour output that is based on these standards.
Let’s say your standards are over on cycle time. A part takes 2:30 to make on average, yet the standard is 3:00. This extra 30 seconds may make the numbers look amazing as you would be 117% to parts goal. Amazing, right? Wrong. This can cause issues with scheduling and results in unplanned downtime.
Now let’s take the opposite cycle time scenario. A part takes 3:00 on average and the standard is 2:30. This extra 30 seconds would mean that you’re 80% to parts goal and are behind.
What information can we, as MachineMetrics, provide to help you with a better understanding of your job actuals, and how do they compare to your job standards? We can tell you the actual cycle time for each individual part made, the average and median cycle times across a job (or operation) run, how much, if any, downtime may be associated with making this part and also how this affects your Optimal Equipment Effectiveness (OEE).
All of this information can be obtained from the MachineMetrics Production Report, which can then be used to update the job standards. We recommend a regular review of these standards to determine if they need an update. This should result in your standards being more accurate, your operators having more realistic expectations, and your customers receiving their deliveries on time.
Job standards are very helpful in determining the performance of your factory. They can provide insight into your production activities and if you are meeting, exceeding, or falling behind goals.
Establish a regular cadence to update your job standards (part cycle time and job setup time, are most common) to ensure you are never that far off and your factory is humming along meeting all your goals.
Want to learn more about how we can help with optimizing job standards? Check out this webinar Using Performance Data to Hone your Job Standards by our Director of Customer Success, Stacy Pease.