defined methods in engineered labor standards

Defined Methods in Engineered Labor StandardsGreg MelroyManager, West Monroe Partners

© 2012 West Monroe Partners | Reproduction and distribution without West Monroe Partners prior consent prohibited 2

Agenda

I. The System, the Process, the Problem

II. The Engineered Labor Standard Process

III.Engineering a Labor Standard

IV.Managing with a Labor Standard

V. Faster, Safer, More Accurate

VI.Questions and Comments


Labor Standards Engineers see more than the bags and the handler

The System, the Process, the Problem


Labor Standards Engineers see the process and tasks

Walk 23 steps around a fuel hose from the tug to the baggage cart, open the luggage cart curtain (A42 B6 G3 A1 B0 P3 A0)

Walk 5 steps to obtain the scan gun, return to baggage cart (A10 B0 G1 A0 B0 P0 A10)

Reach and grab for the luggage, (A1 B6 G3 M3 X0 I0 A0), scan the tag (A1 B0 G1 A1 B0 P3 A0), turn the bag (A1 B6 G3 M3 X0 I0 A0), and finally place the bag (A3 B0 G0 A0 B0 P1 A0)



We want faster, safer, more accurate, more dependable

What happens if we simply build a standard on this process?

Will we achieve the desired results?

Would the process we’re watching get better?



We can easily build a standard on this process, and the employees may do well

But there will be no improvement in the system or the throughput, despite their achievements



So, how do we do it?

How do we build and use an Engineered Labor Standard to get the most out of the system?

How do we get safe, efficient, productive employees to support the overall needs of our systems and processes if an ELS alone is not the answer?



The Engineered Labor Standard Process


An Engineered Labor Standard (or “ELS”) is only as good as the process for which it is built

The system must first be properly dissected and optimized for efficiency

Methods development and documentation followed by workforce training ensure operational success and accountability




Define the System

-Processes-Sub Processes-Tasks

Optimize Processes and Tasks

-Safety-Accuracy-Efficiency

Write Preferred Methods

-"The Right Way"-Every Process-Every Task

Teaching, Training and Accountability


Engineer the Labor Standard

-Work Study-Data Analysis-Elemental Development


Define the Processes of the System



Define the Sub Processes

Process = Baggage Handling• Unload Aircraft• Load Baggage Cart• Drive to/from Aircraft• Load Aircraft



Define the Tasks of a Sub Process

Sub Process = Unload Baggage Cart• Walk from Tug to Baggage Cart 1• Open Baggage Curtain• Obtain Scan Gun• Scan Baggage Tag• Obtain Bag• Place Bag on Belt



Optimize each process

Eliminate non-value added tasks

Change the procedure

Change the job set-up

Look at the process in its entirety – can a simple methods change upstream eliminate a task later?

If necessary, re-build the process from the ground (tasks) up, using the safest, most efficient job set-ups and methods



The question and answer phase of the ELS process may raise as many questions as it answers

The solutions developed during this phase could mean everything to success of the overall system once the ELS has been implemented



Optimizing the Baggage Handler

Can the tug be parked in a different position?

Can the walk to the carts be shortened?

Can the luggage tag be scanned before it is removed from the cart to eliminate the extra handle?

What can be done upstream to improve the efficiency in this process?




Improved positioning of the tug eliminates the need to walk around the fuel hose, eliminating 10 steps (A24 B6 G3 A1 B0 P3 A0)

Adding a holster for the scanner eliminates the need to retrieve the scan gun (A1 B0 G1 A0 B0 P0 A0)

Methods change in loading eliminates the need to turn the bag allowing handler to scan the tag in the cart (A1 B0 G1 A1 B0 P3 A0) then reach and grab for the luggage (A1 B6 G3 M3 X0 I0 A0), and place the bag on the belt without turning it (A3 B0 G0 A0 B0 P1 A0)




The sum of the MOST values for the original process: 1120 TMU (40.28 sec)

The sum of the MOST values once optimized: 620 TMU (22.30 sec)

This is for the first bag only, remaining bags would benefit from only the tag scan and handling (original: 360 TMU, optimized: 230 TMU)

At Atlanta’s Hartsfield-Jackson International Airport where Delta Airlines handles approximately 100,000 bags per day, eliminating the excess bag turn would translate into 130 fewer hours of bag handling per day




Define the System











Once the process has been optimized at the task level, it must be documented thoroughly to avoid any confusion during the training and

follow-up phases



Define the System












Training, Follow-up and Demonstration

Have an effective trainer

Include both written and verbal communication

Include demonstration in the work environment

Schedule follow-up to check for understanding and ensure compliance

Results should be documented



Engineering the Labor Standard


Begin work sampling and operational observation

Build elements based on the written methods and observation

Engineer appropriate allowances

Engineer appropriate variances for conditions

Test and Validate the new ELS

Engineering the Labor Standard


Managing with an Engineered Labor Standard


Front-line management people are the “keepers of the standard”

130% is as bad as 70% on the Operation Reports

Recognition, re-training and accountability are continuous processes

Update the ELS with changing conditions to maintain accuracy

Managing with an Engineered Labor Standard


Faster, Safer, More Accurate


The Engineered Labor Standard is not the “silver bullet” to “Faster, Safer, More Accurate”

An ELS is the final measuring stick for the greater Engineered Labor Standard Process

Successful Engineered Labor Standards are rooted in the properly defined work processes and tasks that are enforced with proper training and follow-up

Faster, Safer, More Accurate


Questions / Comments

defined methods in engineered labor standards

Documents

labor standardmanaging

labor standardfaster

tag a1 b0 g1 a1 b0 p3

bag a1 b6 g3 m3 x0 i0

productive employees

scan gun

efficiency methods development

operational success