Rocksteady & Sigma
Rocksteady
Hey Sigma, I was thinking about setting up a new tuning station. If we break down each step and measure every tweak, we could shave off seconds from our prep time. What do you think about drafting a process map?
Sigma
Draft the process map, label each node with cycle time and output, add a KPI for each tweak, and flag any bottleneck. Every second saved is a market advantage, so make the data crystal clear and eliminate any hand‑off that’s not justified. If a step doesn’t reduce time or increase yield, cut it or replace it. Also, keep a small stack of paperclips for the inevitable paper trail.
Rocksteady
**Process Map – Car Tuning Station**
1. **Step:** Gather parts
**Cycle Time:** 10 s
**Output:** Complete parts list
**KPI:** Parts‑in‑time rate (target 100 %)
**Bottleneck?** No
2. **Step:** Pre‑inspection (visual & code check)
**Cycle Time:** 8 s
**Output:** Tuning sheet
**KPI:** Inspection accuracy (target 99 %)
**Bottleneck?** No
3. **Step:** Engine swap (if needed)
**Cycle Time:** 45 s
**Output:** Engine installed
**KPI:** Swap success rate (target 98 %)
**Bottleneck?** Yes – this is the longest step
4. **Step:** ECU reflash & calibration
**Cycle Time:** 30 s
**Output:** Tuned ECU
**KPI:** Reflash error rate (target <1 %)
**Bottleneck?** No
5. **Step:** Quick diagnostics (bench test)
**Cycle Time:** 12 s
**Output:** Diagnostic report
**KPI:** Diagnostics pass rate (target 100 %)
**Bottleneck?** No
6. **Step:** Final assembly & torque checks
**Cycle Time:** 25 s
**Output:** Fully assembled car
**KPI:** Torque accuracy (target 99 %)
**Bottleneck?** No
7. **Step:** Road test & final tweaks
**Cycle Time:** 20 s
**Output:** Performance data
**KPI:** Road‑test success (target 100 %)
**Bottleneck?** No
**Bottleneck identified:** Step 3 – Engine swap.
**Action plan to cut time:**
- Add a second, trained technician to overlap with Step 2, so the swap can start while inspection is still finishing.
- Introduce a quick‑check checklist before the swap to avoid any back‑tracking.
- Consider a modular engine kit that reduces swap time by 10 s.
**Paperclip stash:** Keep a small stack in the prep area – each step gets a clip to track the data sheet. Done.
Sigma
Looks solid. The engine swap is your choke point; doubling the crew on that step is the simplest ROI tweak. Add a pre‑swap checklist and a modular kit, and you’ll shave the 45 s down to around 35–35 s. Keep the paperclips handy—each clip equals a data point, not just a doodle. All KPIs are realistic; just monitor the swap success rate closely and adjust the training curve. Good map, keep it lean.
Rocksteady
Nice, you’ve got the numbers right. I'll pull up the new swap checklist, test the kit, and set up the extra hand on the bench. The paperclips are in the drawer—every clip’s a metric. If the swap success dips, we’ll tweak the training, not the procedure. Thanks for keeping it tight.