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.

The arithmetic is concrete: with 200 cases in progress and 20 closed per day, lead time is ten days — no matter how hard anyone works. To get to five days without hiring, there is only one route: halve the work in progress. That is why a WIP limit feels wrong at first and works anyway.

From metric to your own numbers

A key figure only means something when it sits on your own operation. Calculate your OEE in two minutes and see where capacity is lost, and how much there is to gain.