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As a high volume/low mix manufacturer, our production scheduling was not complex, but without empowered quality leaders the president and the general manager had to spend a great deal of time running around and trying to keep the situation under control. During the first half of 1 there had been several episodes of bad production scheduling so extreme that some departments had to be laid off for a few days to re-balance the flow of wood. To solve this problem, we posted in Production two large white erasable boards with the list of all the machines in the Shaping and Turning Departments. Once orders were received, management posted on the boards the handle model to be manufactured by each machine, and the quantity needed. The two department leaders had a column where they entered daily the total quantity manufactured by model. There was room for entering data for future jobs as well.
The wood team was composed of leaders from the Planing/Sanding, Cutting, Shaping and Turning Departments. In the late afternoon, the Cutting Department leader went to visit the leaders of the Shaping and Turning Departments. Together, they calculated what wood was needed for the next two days, and how much of it was already cut. The leader of the Cutting Department completed the calculations, and issued his request for the needed wood to the leader of the Planing/Sanding Department (on another erasable board). This last leader notified the management when he was getting short on lumber.
As soon as this independent empowered team began operating, the production scheduling problem disappeared. Amazingly, poorly educated and English speaking supervisors were
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