Simple example of 1 pc continuous flow implementation

1. Lean 1-Pc Flow vs Batch &
Que Production
August 12, 2012
by Julian Kalac, P.Eng
Lean Six Sigma Master Black Belt
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9.  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 bottleneckSource: Improve Phase 26jul07

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

11. 40 min
20 min25 min
15 min
30 min
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•What is the process cycle time?
•What is the process bottleneck?

12.  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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