The first two-day event began the following week. After an initial briefing the team split into three sub-teams, each tasked to complete their study by the end of the first morning. The three cell operators were each involved in a different initial analysis team. The layout team made a cut-out model of the cell and adjacent areas during the first morning, and measured total distances moved. The inventory and material handling team quickly got into questioning the amount of parts stored in the cell (several weeks supply in some cases), and the material movement quantities and methods. The process team chose to get into the ergonomics of the workstations and assembly methods that were the apparent cause of some quality problems. Data collection included measuring inventory, estimating lead times, timing of selected activities (some in greater detail than others), measurement of flow length, and taking photographs.

Immediately after lunch the sub-teams each made a brief presentation to fellow team members. Brainstorming and prioritising took place during the first afternoon. The team spent a good [art of the first afternoon at the cell, discussing alternatives in situ. Some immediate changes were decided upon and a number of airlines and electrical connection points were moved overnight. During the second day, the changes that were actually implemented included: relocation of a small press, the swapping around of a bicycle shed and a storage area, the relocation of a material store in the cell enabling a smoother flow to take place, changes to the assembly process itself, the repair of a door which was causing a draft, a drastic reduction of batch quantities (changeover was already very short), and, as a result, new material handling procedures. Interestingly, some of the women cell operators were initially opposed to any change on the basis of safety, but became enthusiastic supporters when changes proposed by their fellow operators were put in place. The afternoon of the third day was spent prioritising actions, and assigning responsibilities. The list ran to several pages.