Flow Management

by

Best Performing Consulting Organization

Adding Value In Totality !!

The World of Batch-andQueue

In traditional manufacturing, there is a tendency to
run large lots, or batches. This occurs for a variety
of reasonslarge distances between processes, long
setup times, or simply poor processes.
When the batch is transferred to the downstream
process, it sits in line, the part of batch and queue.
Batching and queuing tends to drive up inventory
and lead time, and creates inefficiency in an
operation. It also increases the space needed for
production.

Traditional Method

The World of Batch-andQueue

What happens when you go to your doctor?

Make appointment days ahead

Arrive on time and wait in waiting room
Doctor behind schedule
Referral to a specialist
Laboratory tests
Wait for results
Treatment or medication given
Trip to pharmacy or to specialist
Hospitalization whole new disconnected processes and
waiting

What happens when you take a flight?

What happens when you build a custom home?
As the customer, you pay for all the waiting and rework

Evils of Batch-and-Queue
Increases work-in-process inventory
Hides inefficiencies, lost
opportunities
Lengthens replenishment cycle
Creates finished good inventory
Slows customer response time
Risks obsolete products

Think about ways in Flow?

Line up all of the essential steps needed
to get a job done
Obtain a steady, continuous flow
No wasted motions
No interruptions
No batches
No queues

The Ultimate Factory

Continuous Flow
Producing and moving one item at a time (or a small
and consistent batch of items) through a series of
processing steps as continuously as possible, with each
step making just what is requested by the next step.

It is also called the one-piece flow, single-piece flow,

and make one, move one.
The intent of flow production is to increase the velocity
of products and make the production cycle predictable.

Steady Velocity
Traditional: Batch Production (like a meandering stream with many stagnant pools, waterfalls, and eddies)

When do we get our Parts? 2 WEEKS!

FLOW:Production: Pipeline with fast-flowing water or product

The right Job and it must keep moving

Continuous Flow
Production
Remember!

Make It Flow
Feed the Flow
Link the Flow

What to Flow ?.....

Seven Flows in
Manufacturing

The
The
The
The
The
The
The

flow
flow
flow
flow
flow
flow
flow

of
of
of
of
of
of
of

raw material
work-in-process
finished goods
operators
machines
information
engineering

VSM - to identify
Value in Stream
One
Piece
Flow

Curre
Curre
nt
nt
State
State

6S

Standard
Work

Ideal
Ideal

Future
Future
State
State
Waste

Pull

m
a
e
tr
S
e
u
l
Va

is
s
ly
a
An

Value Stream Mapping

Value stream mapping is the
process of mapping the current
and future status of process.
It maps both material and
information flow.
This mapping is very clear and can
be used as an aid to develop
implementation plan for installing
a lean system.
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VSM current state

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VSM Future state

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Value Stream Mapping

It helps to
Visualize flows
Identify areas of work
Create a common language for
talking about the manufacturing
process
Pull together lean thinking
principles
Illustrate relationships between
information and physical flows

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Steps : Flow Process

1. Redesign layout for flow
2. Link operations
3. Balance workstation capacities
4. Emphasize preventive maintenance
- TPM
5. Reduce lot sizes
6. Reduce setup/changeover time

1. Redesign layout for flow

This complicated flow becomes a much

improves and simpler flow between areas that
are adding value

2. Link operations
Cellular Manufacturing :
Manufacturing in a work cell is termed
as cellular manufacturing.
A cell is a self contained
manufacturing/ service unit for a family
of components where all the facilities
required for manufacture are placed in a
convenient manner.
A work cell is a focused manufacturing
unit .
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Layout change
Before

Bore Honing

Blank Machining

Honing

Drive Slot
Milling

CNC Lathe
Blank Machining

Manual
Manual
Deburring
Deburring

After
CNC Mill
Ho
ni
ng

Drill

Mill

Dbur.

Mill

Hole
Drilling

Lube Slot
Milling

CNC Mill

Drill

Chamfer

Boring
Boring

Boring
Dbur.

Hob

the
La

Out

Hob

Gear
Gear
Shaver
Shaver

Tooth
Tooth
Hole Chamfer
Hole
Chamfer
Boring
Boring
Gear
Shaving

C
CN

CNC Lathe In

Gear
Hobbing

Gear
Shaver

h
C

am

fe

Gear
Hobbing

3. Balance workstation capacities

Balancing is important in practice and
must take into following in to account.
Model mix
Volume
Scheduling system
Labour
Fixed facilities
Capacities
Cycle time
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4. Total Productive Maintenance

TPM aims to achieve zero breakdowns &
stoppages.
TPM aims to solve all the consequences
of equipment problems.
TPM aims to maximise equipment
effectiveness.
TPM establishes a thorough system of
preventive maintenance for the
equipments entire life span.
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5. Reduce Lot size

JIT produces same amount
in same time if setup times
are lowered

JIT Small Lots

A

Time
Small lots also increase flexibility
to meet customer demands

Large-Lot Approach
A

Time

Kanban
Is a signal that:

Authorizes
production

Authorizes
movement

Limits inventory
Drives continuous
improvement

The signal can be a:

Card
Square / Box
Light
Electronic Signal
Racks
Shopping Carts
MRK
( Manufacturing
Ready Kit)

25

Kanban System
Kanban helps:
To deliver right (needed) item at the
right time in the right place and
required Quantity.
To sequence production by clarifying
how much of a specific item must be
produced and transported.
To control the location of material.
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6. Quick setup / changeover

Reducing setup cost reducing
setup time
Setup reduction time is a prerequisite
to lot size reduction
SMED (Single Minute Exchange of
Dies) method
The method has proven its
effectiveness in many companies by
reducing changeover times (nonvalue added times) from hours to a
less than 10 minutes

Continuous Flow Method

Summary of Benefits
Information flow and decision

making enhanced
Value-added ratio improved
Reduces transportation waste
Reduces material handling
Helps to identify root causes of
quality problems
Allows for equipment dedication

Summary of Benefits
Work flow levels are reduced and

progress is visible at a glance

Work team members take
ownership of full process and can
help each other
Quick problem identification and
feedback
Reduced Cycle Time
The ability to cross train is
enhanced

Question ???

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