What Heijunka is & How it Smooths Call Centre Production

The Japanese word Heijunka, pronounced hi-JUNE-kuh means ?levelling? in the sense of balancing workflows. It helps lean organizations shift priorities in the face of fluctuating customer demand. The goal is to have the entire operation working at the same pace throughout, by continuously adjusting the balance between predictability, flexibility, and stability to level out demand.

Henry Ford turned the American motor manufacturing industry upside down by mass-producing his iconic black motor cars on two separate production lines. In this photograph, body shells manufactured upstairs come down a ramp and drop onto a procession of cars almost ready to roll in 1913.

Smoothing Production in the Call Centre Industry

Call Centres work best in small teams, each with a supervisor to take over complex conversations. In the past, these tended to operate in silos with each group in semi-isolation representing a different set of clients. Calls came through to operators the instant the previous ones concluded. By the law of averages, inevitably one had more workload than the rest at a particular point in time as per this example.

Modern telecoms technology makes it possible to switch incoming lines to different call centre teams, provided these are multi-skilled. A central operator controls this manually by observing imbalanced workflows on a visual system called a Heijunka Box. The following example comes from a different industry, and highlights how eight teams share uneven demand for six products.

This departure from building handmade automobiles allowed Henry to move his workforce around to eliminate bottlenecks. For example, if rolls of seat leather arrived late he could send extra hands upstairs to speed up the work there, while simultaneously slowing chassis production. Ford had the further advantage of a virtual monopoly in the affordable car market. He made his cars at the rate that suited him best, with waiting lists extending for months.

A Modern, More Flexible Approach

Forces of open competition and the Six Sigma drive for as-close-to-zero defects dictates a more flexible approach, as embodied in this image published by the Six Sigma organisation. This represents an ideal state. In reality, one force usually has greater influence, for example decreasing stability enforces a more flexible approach.

Years ago, Japanese car manufacturer Toyota moved away from batching in favour of a more customer-centric approach, whereby buyers could customise orders from options held in stock for different variations of the same basic model. The most effective approach lies somewhere between Henry Ford?s inflexibility and Toyota?s openness, subject to the circumstances at the moment.

A Worked Factory Example

The following diagram suggests a practical Heijunka application in a factory producing three colours of identical hats. There are two machines for each option, one or both of which may be running. In the event of a large order for say blue hats, the company has the option of shifting some blue raw material to the red and green lines so to have the entire operation working at a similar rate.

Predictability, Flexibility, and Stability at Call Centre Service

The rate of incoming calls is a moving average characterised by spikes in demand. Since the caller has no knowledge whether high activity advisories are genuine, it is important to service them as quickly as possible. Lean process engineering provides technology to facilitate flexibility. Depending on individual circumstances, each call centre may have its own definition of what constitutes an acceptably stable situation.

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Saving Energy Step 2 ? More Practical Ideas

In my previous blog, we wrote about implementing a management system. This boils down to sharing a common vision up and down and across the organisation, measuring progress, and pinning accountability on individuals. This time, we would like to talk about simple things that organisations can do to shrink their carbon footprints. But first let’s talk about the things that hold us back.

When we take on new clients we sometimes find that they are baffled by what I call energy industry-speak. We blame this partly on government. We understand they need clear definitions in their regulations. It’s just a pity they don’t use ordinary English when they put their ideas across in public forums.

Consultants sometimes seem to take advantage of these terms, when they roll words like audit, assessment, diagnostic, examination, survey and review across their pages. Dare we suggest they are trying to confuse with jargon? We created ecoVaro to demystify the energy business. Our goal is to convert data into formats business people understand. As promised, here are five easy things your staff could do without even going off on training.

Right-size equipment? outsource peak production in busy periods, rather than wasting energy on a system that is running at half capacity mostly.
Re-Install equipment to OEM specifications ? individual pieces of equipment need accurate interfacing with larger systems, to ensure that every ounce of energy delivers on its promise.
Maintain to specification ? make sure machine tools are within limits, and that equipment is well-lubricated, optimally adjusted and running smoothly.
Adjust HVAC to demand ? Engineers design heating and ventilation systems to cope with maximum requirements, and not all are set up to adapt to quieter periods. Try turning off a few units and see what happens.
Recover Heat ? Heat around machines is energy wasted. Find creative ways to recycle it. If you can’t, then insulate the equipment from the rest of the work space, and spend less money cooling the place down.

Well that wasn’t rocket science, was it? There are many more things that we can do to streamline energy use, and coax our profits up. This is as true in a factory as in the office and at home. The power we use is largely non-renewable. Small savings help, and banknotes pile up quickly.

Failure Mode and Effects Analysis

Any business in the manufacturing industry would know that anything can happen in the development stages of the product. And while you can certainly learn from each of these failures and improve the process the next time around, doing so would entail a lot of time and money.
A widely-used procedure in operations management utilised to identify and analyse potential reliability problems while still in the early stages of production is the Failure Mode and Effects Analysis (FMEA).

FMEAs help us focus on and understand the impact of possible process or product risks.

The FMEA method for quality is based largely on the traditional practice of achieving product reliability through comprehensive testing and using techniques such as probabilistic reliability modelling. To give us a better understanding of the process, let’s break it down to its two basic components ? the failure mode and the effects analysis.

Failure mode is defined as the means by which something may fail. It essentially answers the question “What could go wrong?” Failure modes are the potential flaws in a process or product that could have an impact on the end user – the customer.

Effects analysis, on the other hand, is the process by which the consequences of these failures are studied.

With the two aspects taken together, the FMEA can help:

Discover the possible risks that can come with a product or process;
Plan out courses of action to counter these risks, particularly, those with the highest potential impact; and
Monitor the action plan results, with emphasis on how risk was reduced.

Find out more about our Quality Assurance services in the following pages:

Field service and customer transparency

These days, a business is as good as it is transparent. Businesses are on unsteady ground because of the ever changing face of social media and a never-seen-before demand for information. With many sources of info on the internet, being credible is a sure way of building trust and loyalty among clients.

Here is an example. Customers will always believe what they see. If they see the work you put into furnishing their favourite products, you have a greater chance of getting their approval. They can invest more in what they see. The clothing merchandise Patagonia did this for their Footprint Chronicles line to show how their jackets are made and worked out fine for them.
Transparency is a must. Nowadays, customers never forget when they feel cheated. It is even harder to ensure transparency because many clients are also experts who scrutinise every detail. So, how can you keep transparency at the forefront?

Have transparent workforce management

Customers always look for new information and want to be in the know. There is nothing worse than not being able find a product manual or an easy way to set up appointments. By giving your clients a self-service option, they can pick the services they want. This leaves more time to get stuff done rather than answering unending service calls from dissatisfied customers.

For instance, you could have a field service customer self-service application that allows customers to look for personalised services, a machine manual, book appointments, or solve any other problem. Customers then get feedback anytime. This one-on-one approach can help customers feel like their questions are being answered. They?ll also not go through the hassle of long hold times to reach an available customer service representative.

Create transparency in field service repair projects

If field technicians have access to field service software, it allows technicians to be more open to customers. This gives them vital information like customer history and the ERP, so that they can explain changes that were made after past enquiries and what is being done in current products. Such information can be a guide for future updates or let the techs suggest products that suit a client’s taste. Unlike always staying offline and out of touch with your client, using field service software can allow entry of allowances and mileage, and also let the customer know the delivery time for their products.

Show customers what they’re paying for

With field service automation, billing will also be transparent. By using the available information about your field service solution, the station can send updated service reports to the customer like mileage, allowances, parts, hours worked, and photos of broken parts from the service. After the customer authenticates the transaction with a signature, the field service agent can generate and sent to the customer an invoice based on the agreed upon services. In case allowances and mileage can be forwarded to the customer, it will be shown on the invoice.
Because you use field service automation, it means that the customer will receive the invoice really fast ? in days rather than weeks ? and transparency will skyrocket because the whole experience of the service will leave a permanent mark in their mind.

Mistaking information for transparency

Being honest with your customer is the one thing. Wasting their time with unnecessary information is another. Here is an experience I had with a small retailer. Tracking information is only useful if it has recent updates and is accurate. If the company want to use real time tracking, let them do so under one condition ? updates should be regular and on time so as not to leave the customer frustrated because they also make plans based on the same information. Late updates shed light on the nature of the service command. Everyone hates cooked-up real time information.

A company must not always have a one to one exchange of information with customers to maintain transparency..

Use simple language that all customers can understand
Don’t use abbreviations that only employees know
Never ever air your failures and flaws to your customers

It is interesting that most of the tools we use to keep in touch with our clients and servicing their requests can also be used to gather data and iron out possible errors to improve products and services. This is a good chance for service providers to evaluate and make necessary amendments.

There are some areas that will need improving while others will not, nevertheless, the client needs to always be informed and know why things are the way they are. Not all details should be told, so filter what you share.

5 ways field service supports customer service

Sales organisations are always in motion, working to deliver the right product to their customers. To keep customers smiling all times is hard and only needs close communication and fulfilling promises that were made to them. This is where the field service delivery team comes in. Field service can either meet this demand or fall short plummeting satisfaction rates.
This is a task that relies on right people using various parts and information to get the job done. No matter what, the customer always expects to get exceptional services whether it be over the phone, chats, in the field, online messaging, over email, or social media.

These five field service points are suitable for any business model and guarantee excellent company-client relations.

Proactive service

A proactive service gives more to the customer. More attention is given to the customer so that the right actions, deliveries and repairs are done. By getting everything right the first time, the customer has less to do ensuring that they are satisfied with the services.
However, the field service technician is flooded with a myriad of unpredictable situations; overheating equipment, stalled machines, and insufficient precaution. But through field management software, they get more data about the customer and type of service or parts expected and they easily ride through any storm and prevent future damage.

Transparency

Nothing frustrates a customer more than a schedule that delays repairs. They easily ditch you for better services elsewhere. By offering the customer a service where they book appointments based on their own availability, we can easily sync this to the technicians and manager?s calendar. This not only saves time but also money from otherwise idle equipment.

On-site and off-site collaboration

Having seamless communication between field and office technicians is vital. Field technicians need to know more about parts, repairs, client maintenance history, and predict what should be changed in the long run. The faster they do this the better.

There should be a system that creates and automates communication between field and office technicians. Let each have the upper hand when providing parts, products or services to the customer.

Flexibility

Information is key to field service agents. They make the first impression since they make the initial contact with clients. Regardless of the resources, the field technician must always be armed with mobile tools they will need to access online resources and be ready for any emergency.

Actionable performance improvements

Customers demand excellent service a company could offer. But as the game constantly shifts, the service management technicians must also come up with plans to stay up to par with competition. All these stems from coming up with KPIs, measuring them and turning them into a workable plan for the future.