Batch v Lean 1 piece flow training
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This document discusses lean 1-piece flow versus batch and queue production. It defines a bottleneck as the point that reduces flow or slows the entire process. It notes that bottlenecks will always exist and can move, and that high work-in-process can mask bottlenecks. The document recommends setting up equipment close together to pass parts without boxes and running one order at a time in a cell until completion to implement 1-piece flow. It also includes an exercise to compare batch and 1-piece flow.
Batch v Lean 1 piece flow training
- 1. Lean 1-Pc Flow vs Batch & Que Production August 12, 2012 Developed by Julian Kalac, P.Eng Lean Six Sigma Master Black Belt 1
- 3. 5 S IN B-VENT AREA-BEFORE 3
- 4. BEFORE 5 S 4
- 6. B-VENT AFTER 5 S 6
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- 9. Source: Improve Phase 26jul07 Bottleneck Management • Bottleneck – The point which is currently reducing the flow or slowing the entire process – A managed buffer before a bottleneck is necessary – A bottleneck WILL exist in every process – Bottlenecks move ! – High WIP can mask the bottleneck – The people working at the bottleneck take breaks, not the bottleneck
- 10. • Workers can do each others work, help out when someone is sick, on holidays, quit • Workers help improve bottleneck operations by helping out each other • Variety in work making it more full-filling • Training new workers Benefits of cross functionally trained workers
- 11. QUESTION ON CYCLE TIME 40 min 20 min25 min 15 min 30 min 1 54 3 2 •What is the process cycle time? •What is the process bottleneck?
- 12. HOW TO SET-UP 1-PC FLOW? • GET ALL YOUR NEEDED MATERIAL BEFORE YOU START!! • Set-up equipment as close as possible together so you can pass parts without using boxes • Eliminate WIP BOXES • Set-up a white board and record hourly PPMH compared to target. • List any issues you have during the run • Run 1 order at a time in the cell until it’s completed and then next order 12
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- 14. 10 min exercise on Batch and 1 Pc flow 14
- 15. Next we set-up 1-pc flow in components 15
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