Using the complexity index method to manage problems related to manufacturing

Abstract The Complexity Index method is an approach developed to help manufacturing companies quantify complexity in production. This paper sheds light on the connection between complexity and manufacturing problems and how the Complexity Index method was used to capture the areas in a production line with high levels of complexity to determine the sources of manufacturing problems related to labour time, surplus production, and manufacturing error. The main areas perceived as complex were due to Work Instructions, Work Content, and Product Variants. The perceived complexities were assessed for proper actions to be taken to decrease their level of complexity. The correlations between complexity and manufacturing problems were used for tracking related issues and ways for improvement. This study presents data on the use of workers’ perception to uncover the areas of complexity, which could be used by the management team to pragmatically capture difficulties and issues related to manufacturing problems to improve the production system.