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
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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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