For any business, efficiency is key to success. However, one of the biggest challenges in production is managing variability, which comes in two forms: natural variability and variability caused by inefficiencies. In this discussion, I will focus specifically on Mura—variations caused by inconsistencies and irregularities in production due to poor management practices—rather than natural variability, which is inherent to any operation.
As an operations manager, one thing I have learned is that operations are non-linear. Relying on average production times is highly inefficient because it ignores the fact that processes fluctuate for multiple reasons. Failing to account for this variability can lead to significant financial losses for a business.
This is why controlling Mura is critical. I am fully convinced that if a business doesn’t control Mura, production costs will rise, and sooner or later, it will struggle to meet customer demand in both quantity and quality. This can become one of the biggest threats to the business’s survival.
To understand Mura, let’s take the example of a nursery that prepares and packs plants for shipment. The process includes several steps: selecting plants for each order, preparing them, wrapping them for protection, and packing them into boxes.
For illustration purposes, let’s say an employee is tasked with selecting 300 plants for an order. The time it takes to complete this task will depend on factors such as plant quality and the selection process. If we assume for this example that the time required to complete the selection varies between 30, 60, or even 90 minutes due to inconsistencies in quality and process efficiency, it becomes clear how unpredictable work times can create an imbalance in production. This kind of variability leads to bottlenecks that could be prevented by addressing Mura
if Mura is not controlled, workers in preparation and packing stations will either receive too few or too many plants at once. This creates two major problems:
Overproduction, when too many plants are processed at once, increasing the chances of damaging the product.
Underproduction, when there aren’t enough plants available, driving up operating costs and hurting employee morale due to wasted time.
How to Reduce Mura in Production
• Improve communication with management about quality issues and process variations. This helps ensure better plant selection and stronger coordination with suppliers.
• Standardize processes to reduce inconsistencies and ensure each step takes a consistent amount of time. This makes production more predictable, smooths out workflow, and helps prevent bottlenecks.
• Analyze production data to identify and correct sources of variability, and ncourage employees to report problems and suggest process improvements helps create a more efficient and responsive work environment.
Conclusion
Mura, or variability caused by inefficiencies in management and production processes, is a hidden issue in production. It often shows up in bottlenecks, inconsistent product quality, and poor workflow organization.
By improving communication, standardizing work, and continuously refining processes, supervisors can reduce Mura and build a more stable, predictable production system. Understanding and controlling Mura is crucial for keeping operations efficient and profitable—and for advancing in yout management career.
By Miguel Gonzalez
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