Insights
How factories actually lose time.
Queueing, utilisation, and manufacturing critical-path time — written for people who run plants.
Why high machine utilization can increase manufacturing lead time
High machine utilization increases lead time by inflating queue time. Above roughly 85% utilization, waiting stops rising gently and starts rising steeply.
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Why most manufacturing lead time is waiting, not processing
A part that takes four hours of real work routinely takes four weeks to reach the customer. The gap isn't slow machines — it's queue time, and it follows predictable mathematics.
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Manufacturing Critical-Path Time (MCT): a better way to measure lead time
MCT counts every calendar day an order truly takes — weekends, waiting, approvals, outside processing — from order entry to first piece delivered.
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What is Quick Response Manufacturing (QRM)?
A factory can be busy all day and still be slow. QRM attacks calendar time — waiting, queues, WIP, and handoffs — rather than chasing machine utilisation.
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The QRM Response Time Spiral: why long lead times create even longer lead times
Long manufacturing lead times encourage earlier release, more WIP, larger batches, and expediting — which grow queues and stretch lead time again.
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