Lean 1-Pc Flow vs Batch & Que Production

August 12, 2012

Developed by Julian Kalac, P.Eng

Lean Six Sigma Master Black Belt

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5 S IN B-VENT AREA-BEFORE

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BEFORE 5 S

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B-VENT AFTER 5-S

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B-VENT AFTER 5 S

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Process/Material Flow

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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

• 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

QUESTION ON CYCLE TIME

40 min

20 min 25 min

15 min

30 min

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•What is the process cycle time? •What is the process bottleneck?

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

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10 min exercise on Batch and 1 Pc flow

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Next we set-up 1-pc flow in components

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