Training with Before and After pictures

1. 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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3. 5 S IN B-VENT AREA-BEFORE
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4. BEFORE 5 S
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5. B-VENT AFTER 5-S
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6. B-VENT AFTER 5 S
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7. Process/Material Flow

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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
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•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
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15. Next we set-up 1-pc flow
in components
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