MenuClose

Findings

Exhibits

Every exhibit makes one point, states it in the title, and carries its unit and source. The exhibits below use illustrative data.

Vernier calipers with blank scales resting on a ground steel plate.

  • The fix only one person knows / Exhibit 1

    Illustrative data

    In this illustrative bottling plant, more than half of the skilled maintenance team has 21 or more years of service

    Skilled maintenance headcount by years of service, illustrative bottling plant

    Note
    Illustrative data for layout purposes only; not a research finding. Brass marks 21 or more years of service.
    Source
    The Craft Gap, illustrative data set (placeholder). Real exhibits name the survey, sample size and date.
    From
    The fix only one person knows
    View the data
    In this illustrative bottling plant, more than half of the skilled maintenance team has 21 or more years of service (Skilled maintenance headcount by years of service, illustrative bottling plant)
    CategoryValue
    0–214
    3–59
    6–106
    11–157
    16–2010
    21–2517
    26–3021
    30+16
    Link to this exhibit: In this illustrative bottling plant, more than half of the skilled maintenance team has 21 or more years of service

  • What a good shift handover sounds like / Exhibit 1

    Illustrative data

    In this illustrative bottling plant, a walk-down at the machine passes on more open issues than a logbook

    Share of open issues fully passed on at shift handover, by handover format, percent, illustrative bottling plant

    Note
    Illustrative data for layout purposes only; not a research finding.
    Source
    The Craft Gap, illustrative data set (placeholder). Real exhibits name the survey, sample size and date.
    From
    What a good shift handover sounds like
    View the data
    In this illustrative bottling plant, a walk-down at the machine passes on more open issues than a logbook (Share of open issues fully passed on at shift handover, by handover format, percent, illustrative bottling plant)
    CategoryValue
    Logbook entry only38%
    Verbal handover at the desk52%
    Walk-down at the machine74%
    Link to this exhibit: In this illustrative bottling plant, a walk-down at the machine passes on more open issues than a logbook

  • Map the tasks that would hurt most to lose / Exhibit 1

    Illustrative data

    In this illustrative bottling plant, three critical tasks have a shift with no one qualified to do them

    Number of people qualified to perform each critical task, by shift (skills matrix), illustrative bottling plant

    In this illustrative bottling plant, three critical tasks have a shift with no one qualified to do them (Number of people qualified to perform each critical task, by shift (skills matrix), illustrative bottling plant)
    Shift AShift BShift CShift D
    Boiler start-up after trip 3 2 1 1
    Labeler changeover 2 2 2 1
    CIP sequence recovery 1 0 · gap 1 0 · gap
    Ammonia refrigeration fault-finding 2 1 0 · gap 1
    Palletizer jam clearing 3 3 3 2
    Filler valve rebuild 1 1 0 · gap 0 · gap
    Note
    Illustrative data for layout purposes only; not a research finding. Dashed cells mark a shift with no one qualified.
    Source
    The Craft Gap, illustrative data set (placeholder). Real exhibits name the survey, sample size and date.
    From
    Map the tasks that would hurt most to lose
    Link to this exhibit: In this illustrative bottling plant, three critical tasks have a shift with no one qualified to do them

  • Learning curves are longest where retirements come first / Exhibit 1

    Illustrative data

    In this illustrative bottling plant, technical roles take the longest to reach unsupervised competence

    Months from hire to working unsupervised on the full task set, by role, illustrative bottling plant

    Note
    Illustrative data for layout purposes only; not a research finding.
    Source
    The Craft Gap, illustrative data set (placeholder). Real exhibits name the survey, sample size and date.
    From
    Learning curves are longest where retirements come first
    View the data
    In this illustrative bottling plant, technical roles take the longest to reach unsupervised competence (Months from hire to working unsupervised on the full task set, by role, illustrative bottling plant)
    CategoryValue
    Production operator6 mo
    Shift supervisor14 mo
    Mechanical maintenance technician24 mo
    Process engineer30 mo
    Electrical and instrument technician36 mo
    Link to this exhibit: In this illustrative bottling plant, technical roles take the longest to reach unsupervised competence