01 — Problem-Solving
Solution-Oriented Approach in Tangible Production Processes
From Bottlenecks to Flow: Enhancing Productivity Through Team Adaptability
In my experience working within a production process, I observed a common challenge: internal stakeholders would submit orders, and each team member would pick one to work on. However, some orders were significantly longer than others. When these extended tasks caused delays, certain stakeholders received their products much later than expected since only one person was working on them. This created frustration, especially for those who had submitted their requests first but received their deliveries last. Additionally, it led to bottlenecks, as only one operator handled lengthy orders while others, having completed their tasks, were left with lower-priority work.
Taking Action for a More Efficient Workflow
My role was to process incoming orders and ensure they were ready for internal stakeholders. However, I quickly realized that a rigid system—where each worker focused on a single order at a time—was not the most efficient approach. Instead of following the existing workflow, I took a step back to analyze:
1. Understanding Process Dependencies – I examined the production flow to identify which products required pre-processing, additional work from other departments, or machine setup.
2. Recognizing Team Strengths – I assessed my team’s expertise, considering not just speed but also attention to detail. This allowed me to assign tasks to the right people based on the complexity and precision required for each product.
3. Daily Adaptive Reorganization – Rather than following a fixed order for task execution, we reorganized the team daily based on workload. Similar tasks were grouped together to be processed simultaneously, and for high-priority orders, multiple team members collaborated to complete them faster.
4. Collaborative Execution – For long orders, instead of leaving one operator to handle the entire process alone, the team worked collectively on the most time-consuming steps. This way, once the initial stages were completed, only one person needed to finalize the task.
The Results: A More Flexible and Efficient Workflow
This new approach allowed us to work on multiple orders simultaneously, reducing idle time and improving delivery speed. Stakeholders experienced shorter waiting times, and the production team operated more efficiently. Additionally, this fostered greater rapport and cohesion among team members, creating an atmosphere of collaboration. By shifting from a rigid structure to an adaptive, team-driven model, we eliminated bottlenecks and ensured a smoother, more productive workflow—proving that small operational changes can make a significant impact.