The Effects of Employee-Led Process Design on Welder Set-Up Intervals

This study focused on improving manufacturing efficiency and production by designing new steps to the work process with an employee focus group. The set-up behaviors of two regular stock welders at a medium-size metal furniture manufacturer were observed via video recordings. The videos of the welders completing their tasks were reviewed in an employee focus group, during which it was determined that designing the welding process to include the use of walkie-talkies would successfully alter the contingencies surrounding set-up behaviors, thereby leading to a decrease in average set-up time. Results for the two welders combined showed a decrease in average set-up time of 2.27 min, with Welder A exhibiting a larger decrease overall and Welder B’s set-up time showing a greater reduction in variability.