Breaking The Time Barrier Series
Written by: James K. Allred

In Advice to a Young Tradesman, published in 1748, Benjamin Franklin offered the observation that "time is money." Although many of us are involved with total quality practices and employee empowerment, and have streamlined the process of getting products to market, few have yet undertaken to think anew the total manufacturing process. That is, breaking the time barrier that thwarts significantly reduced cycle time and the achievement of world-class manufacturing.

Why has the time barrier been so hard to break? One reason may be that we continue to try and "fix" our current systems instead of revamping our whole approach to factory logistics. In most cases, the investments made in advanced manufacturing equipment were directed at individual work stations, without regard for movement and control of work between stations. Turning to the computer for help, we generally automated the obsolete systems we already had. Result? We improved data flow, but not materals flow, and the time barrier remained intact.

The tools we need to knock down time-barrier obstacles may be found in our approach to the major materials handling system variables-distance, time, place, sequence, accuracy, and condition. Thus, when our operations involve long travel distances, wasted time, misplaced and misdelivered material, double handling, poor inventory control, and damaged parts, the results far too often are frenetic activity, confusion, and unhappy customers. Even when parts and subassemblies are bar coded, all too often we get material into the "system" only to place it in a remote, unsecured storeroom, or even on the factory floor, where it is moved repeatedly and often lost.

By automatically buffering and moving parts to the workers, we eliminate this inefficiency by offering real-time 100% accurate parts tracking in a physically controlled environment. All material transactions are recorded automatically using bar codes, usually without the need for a single paper form, while operator prompts and built-in editing functions eradicate errors. Security codes allow access only by authorized users and stop "midnight requisitions'. The time barrier is finally broken. Jobs are more interesting and challenging, and employee morale and productivity soar.

Future columns will provide details on breaking the time barrier, covering such factors as real-time inventory control, empowered workers, moving materials through the factory, and controlling external forces.

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