How to Develop New and Improved Working Methods?

In the last few weeks, I have talked about how to solve problems and improve processes using statistical thinking; you can look here, here, here and here!

But does every operation need this seemingly cumbersome process to be improved?

Luckily not.

Whether you work in a manufacturing or service sector, you will find this technique, which I'm about to share with you today, is extremely beneficial.

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Processes and procedures often become complicated over time.?

Business needs, new technologies, and rules make workflows more complex. This extra complexity causes problems.?

It slows things down, it wastes money and resources, and it leads to mistakes.

The ECRS technique is a way to develop new working methods that was developed by the Training Within Industry (TWI) program in the 1940s.??

It provides a straightforward methodology for developing new and improved working methods, as well as optimizing processes.?

ECRS stands for Eliminate, Combine, Rearrange, and Simplify. By methodically working through each step, you can dramatically improve efficiency, quality, and productivity.

Let’s take a look at each step and common examples.

1) Eliminate

The first goal is to eliminate any steps in the production process that are unnecessary or do not add value. For example:

• Removing quality checks that are redundant or no longer relevant due to upgrades in technology.
• Eliminating reporting requirements for metrics that are no longer used for production decisions or performance management.
• Discontinuing use of older equipment that is outdated but not yet fully phased out of workflows.
• Discarding process documentation that has become obsolete.

The key is to critically evaluate each activity and remove those that do not contribute real value in terms of quality, cost, or customer requirements.

2) Combine

Next, examine steps in the workflow that can be combined or consolidated. For instance:

• Using a single multifunctional testing device rather than separate instruments.
• Integrating filing or documentation requirements into a single digital system.
• Merging some daily team meetings when agendas overlap.
• Cross-training staff to perform multiple functions rather than hand-offs.

Carefully combining steps reduces redundancies and hand-offs while simplifying training and communication needs.

3) Rearrange

With fewer steps after streamlining, analyze the ideal sequence to optimize workflow. Examples include:

• Rescheduling plant shifts to better balance workloads.
• Moving quality inspections earlier in the process to prevent rework.
• Reorganizing machinery layout into manufacturing cells.
• Paralleling dependent steps so they can happen simultaneously rather than sequentially.

Strategically rearranging the order and timings of activities can significantly improve plant flow.

4) Simplify

Finally, consider how to simplify individual steps in the redesigned production workflow. This may involve:

• Standardizing workflow within cells.
• Automating repetitive tasks through technology.
• Posting visual work instructions at machine stations.
• Using fixtures, guides, or templates to reduce errors.
• Color coding tools or materials for faster visual identification.

Simplified steps allow workers to be accurate and consistent while wasting less time and motion.

The ECRS technique provides a structured framework for continuously developing new and improved working methods and optimizing processes.

Regularly examining your workflows through the ECRS lens will yield production improvements over time. The gains compound through faster output, higher quality fewer mistakes, lower rework, and reduced costs.

References:

• War Production Board, Bureau of Training, Training Within Industry Service, 1943, Job Methods: Sessions Outline and Reference Material
• Smalley, A. (2021, April 8). Art of Lean - Website for Art of Lean, Inc. Retrieved from https://artoflean.com/

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