The four drivers of WFM, workplace organization (WPO), uninterrupted flow (U-flow), error-free processing, and insignificant changeover, differ from other approaches in that they provide you with the means to rapidly deploy the waste-free process.

In the most fundamental terms, the work force, key implementors and champions, in particular, must see that the process of WFM starts with a solid foundation of continuous improvement and that foundation is WPO. You must fully implement this foundation for WFM to have any chance of being rapidly deployed.

Unlike 5S, 6C, with its six different performance levels (rather than lumping all five categories of 5S on rating on a scale of 1 to 5), will give you the kind of measurement that can't mislead employees as to where they stand in the process. Furthermore they cannot move to the next step until the previous one is fully in place.

The better an operation flows in an uninterrupted manner, the fewer parts required in the overall work-in-process change. The fewer parts required, the less scrap, rework, and obsolescence required. When you eliminate disruptions in flow, one-piece flow becomes a result and you accomplish U-flow.

Equipment and facilities may have to move numerous times in pursuit of achieving a true WFM environment. Equipment relocation is a must and over a period of time can become a major operating expense. But the rewards will more than justify any of the associated costs.

You cannot successfully achieve error-free processing unless you perform the appropriate root...