Lean 1-Pc Flow vs Batch & Que Production

August 12, 2012

by Julian Kalac, P.EngLean Six Sigma Master Black Belt

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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

Source: Improve Phase 26jul07

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

40 min

20 min25 min

15 min

30 min

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

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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