Metrics & analysisWork in Progress

What is WIP (work in progress)?

WIP (Work in Progress) is all work that has been started but not finished: items between processes, cases under handling, orders in the system. High WIP lengthens lead time proportionally (Little’s law), ties up capital and hides problems.

WIP feels productive — everyone is busy — but every started item that is waiting is wasted calendar time and hidden risk: errors discovered late, priorities that change, switching between tasks.

WIP ceilings (as in kanban) are the simplest countermeasure: set a maximum for how much may be in progress per process, and start something new only when something is finished. Stop starting, start finishing.

Related concepts

Lead time

Lead time is the total time from an order or item starting in the process until it is finished and delivered — including all waiting and inventory time. It differs from process time, which is only the time actively worked on the item.

Kanban

Kanban is a signalling system that controls production and replenishment based on actual consumption: a card, an empty space or an electronic signal grants permission to produce or deliver a fixed quantity. Kanban is the practical mechanics behind the pull principle.

Flow

Flow means an item or a case moves through the process without stops, accumulation or waiting. Perfect flow is one-piece production: each item is processed and passed on immediately.

From concept to practice

The methods only work when they are anchored in daily routines and leadership behaviour. The operations check shows in 4 minutes where your operations stand — and what the next step is.

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