Using Multiple Regression to Improve Front Line Worker Morale
Stephen W. Czupryna, Consultant, ObDOE
Productivity and costing metrics like units per hour are commonly used in industry for planning and management purposes. However, these metrics are fair to front line workers only if the units under production have comparable cycle times. For custom ankle-foot orthotic braces, dramatic differences between braces and the amount of work needed to produce them are the norm. For example, there are many different designs of braces available to treat a wide variety of walking dysfunctions. Some designs are relatively simple while others are complex with hinges, support structures, inner liners and the like. And of course, there is wide variation in the geometry of people’s lower leg, so braces range from tiny, short & narrow to large, tall & wide. Therefore, for ankle-foot orthotics, common factory metrics such as units per hour don’t fairly measure front line worker productivity, particularly for the edge finishing processes. The result is disputes and out-of-sequence selection of small braces through no fault of the front line worker. An equitable metric like weighted units per hour was badly needed.