Tiếng Việt
In modern manufacturing, managing task time, cycle time, and lead time plays a central role in achieving operational efficiency. As we enter the Lean 4.0 era—where digital technologies, IoT, AI, and big data converge with Lean thinking—businesses are faced with both new opportunities and challenges.
In particular, task time is not only a metric for measuring labor productivity but also reflects the ability to standardize, automate, and optimize the entire system. However, managing task time in a digitalized environment faces several barriers: from fragmented data and unadapted personnel to the lack of synchronized technology integration.
This article will analyze the 10 biggest challenges in managing task time, cycle time, and lead time, while providing practical solutions for businesses to operate effectively in the context of Lean 4.0.
Lack of standardization in task time measurement
Challenge:
Many companies still lack a standardized system for measuring task time, leading to data inconsistencies and making it difficult to compare between work shifts or production lines.
Solution:
Develop a unified set of measurement standards and apply IoT technology to record real-time data. At the same time, train employees on the concept of task time to ensure clear understanding and proper compliance with regulations.
2. Fragmented and Unintegrated Data
Challenge:
In Lean 4.0, data on task time, cycle time, and lead time is often scattered across multiple systems (ERP, MES, Excel), making analysis difficult.
Solution:
Integrate data into a centralized platform and develop an intuitive dashboard that enables comparison of task time across departments and identification of process bottlenecks.
3. Variations Caused by Human Factors
Challenges:
Task time is greatly influenced by employees’ skills, mindset, and health. An inconsistent manual operation can prolong the production cycle.
Solution:
Standardize operations, provide continuous training, and apply supportive technologies (collaborative robots, AR/VR guidance). The goal is to minimize dependence on individual factors and stabilize task time.
4. Difficulty in Linking Task Time with Cycle Time and Lead Time
Challenge:
Companies often track these metrics separately, leading to a lack of connection. Meanwhile, task time serves as the foundation for calculating cycle time, which in turn directly impacts lead time.
Solution:
Develop an integrated measurement system — task time → cycle time → lead time — that enables forecasting the impact of every change at the smallest task level on the entire value chain.
5. Lack of Root Cause Analysis Tools
Challenge:
When task time increases abnormally, many companies address only the surface issues instead of identifying the underlying root causes.
Solution:
Apply Lean tools such as the 5 Whys and Ishikawa diagram in combination with digital data to analyze root causes. This enables sustainable process improvements instead of temporary fixes.
6. Challenges in Digital Technology Integration
Challenge:
Not all companies have the resources to implement technology for real-time task time monitoring. High investment costs and a shortage of IT personnel are common barriers.
Solution:
Implement gradually, starting with critical areas. Use moderately scaled technologies (e.g., low-cost sensors, cloud-based software) before expanding to the entire plant.
7. Lack of Frontline Employee Engagement
Challenge:
If task time is managed solely from a managerial perspective without worker involvement, the data may be inaccurate and difficult to apply in practice.
Solution:
Encourage employees to participate in recording, feedback, and proposing task time improvements. Build a Lean culture where everyone contributes to reducing waste and enhancing efficiency.
8. Pressure to Shorten Lead Time While Overlooking Task Time
Challenge:
Companies often focus on shortening delivery lead time while neglecting to optimize task time at each small process stage. This results in unsustainable improvements.
Solution:
Start with small improvements—optimize each task time first, then expand to cycle time and lead time. This reflects the spirit of Kaizen — continuous improvement in Lean 4.0.
9. Difficulties in Forecasting and Planning
Challenge:
When task time fluctuates, production planning becomes inaccurate, leading to late deliveries or excessive inventory.
Solution:
Apply AI and predictive analytics. Algorithms can learn from historical task time data to forecast production capacity, enabling more accurate planning.
10. Lack of Connection Between Task Time and Customer Value
Challenge:
Companies sometimes optimize task time solely to increase internal productivity, without creating real value for customers (e.g., reducing time but compromising quality).
Solution:
Balance speed and quality. Every task time improvement should be linked to enhancing the customer experience — delivering better-quality products, faster service, and more reasonable costs.
Conclusion
In Lean 4.0, managing task time is not merely about measuring how long a task takes — it represents a comprehensive management strategy. The ten challenges and solutions above demonstrate that to manage effectively, companies must combine Lean thinking with digital technology.
Optimizing task time helps stabilize cycle time, thereby shortening lead time — resulting in higher productivity, reduced waste, and greater customer satisfaction.
Any company that masters and successfully implements task time management within Lean 4.0 will gain a significant competitive advantage on its digital transformation journey.
