Breaking Complex Processes Into Manageable Chunks

Steve Goode identified a problem with receiving at Magna Park where there was a large amount of variables both in phone type and the faults that they had, which made it a very complex to process to receive them and get them in the right place to repair them.

After a visit to Baginton B to observe their ten minute challenge which looks to break down complex processes into smaller, more manageable chunks, Steve brought the principle back to Magna to see if it would work on his processes.

The first step was to understand the best way to handle the returns, so after attending the Six Sigma Greenbelt training, Steve used data to get through the complexities of the process, and understand the best way to handle the variables and smooth the flow into the repair lines.

Once the team understood what the data was telling them, they created an express process and an advanced one which allowed them to increase throughput.

After the new processes had been bedded in, they then measured the improvements which showed they achieved £127,000 cost saving, improved the lead time for the customer and reduced training time for the team members to perform the process from three weeks to a couple of days.

Watch Steve’s story in the video below.