Why Routing Optimization Matters

In a typical job shop, a work order visits 4-8 work centers before completion. Each transition is an opportunity for delays: queue time, transport time, setup time, and the ever-present "where did that job go?" problem.

Optimizing your routing strategy can cut lead times by 50% or more — without adding machines or people.

Strategy 1: Eliminate Unnecessary Routing Steps

Review your standard routings quarterly. Are there inspection steps that could be combined? Operations that modern tooling has made redundant? Every step you eliminate removes queue time and handling.

Strategy 2: Batch Similar Setups

Group work orders that share similar setups, materials, or tooling. Running five jobs with the same fixture back-to-back saves four setup cycles compared to interleaving them with other work.

Strategy 3: Create Express Lanes for Hot Jobs

Designate specific machines or time windows for rush orders. This prevents hot jobs from disrupting the entire floor while ensuring they get priority treatment.

Strategy 4: Track and Reduce Queue Time

Most of a work order's lead time is spent waiting, not being processed. Track queue time at each work center and set targets. Digital tracking systems make this visible for the first time.

Strategy 5: Implement Pull-Based Scheduling

Instead of pushing all work orders to the floor simultaneously, release work based on downstream capacity. This reduces WIP, shortens queue times, and makes the floor more manageable.

Measuring Success

Track these metrics monthly: average lead time, on-time delivery percentage, WIP count, and queue time by work center. Improvements in these numbers directly translate to customer satisfaction and profitability.