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Creating Continuous Flow

The document discusses the benefits of continuous flow manufacturing over batch processing. Continuous flow reduces lead times, improves quality by making issues quickly apparent, and encourages communication between linked operations. While ideal, true continuous flow is limited by equipment like stamping machines that require setup changes or cannot meet minimum cycle times. Still, lean systems are making progress through improvement efforts and innovative equipment designs dedicated to product families.

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166 views

Creating Continuous Flow

The document discusses the benefits of continuous flow manufacturing over batch processing. Continuous flow reduces lead times, improves quality by making issues quickly apparent, and encourages communication between linked operations. While ideal, true continuous flow is limited by equipment like stamping machines that require setup changes or cannot meet minimum cycle times. Still, lean systems are making progress through improvement efforts and innovative equipment designs dedicated to product families.

Uploaded by

Adi copycenter
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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• Shortened lead time, which permits quicker response to the customer and a shorter

'money conversion cycle' (time between paying for raw material and getting paid
for the products macle out of those raw materials.)

• Problems such as defects quickly become apparent instead of remaining hidden.


Problems can be identified quickly and corrected before proceeding. lt is easier
toidentify root causes of abnormalities when they are detected as they occur.

• Encourages communication between operations, which become linked in


"customer-supplier" rela tionships.

Any item produ~ed before it is actually needed by the next procesşing step creates waste,
such as extra handling, counting, storage, and so on. When you see batching of even one
extra piece you should realize that you have used an operator's time to process and handle
an item that was not yet needed. You could have used that person's time and skills to
process something that was needed!

When you take a clase look at most factories, it doesn't take long to see that although
people are busy, the great majority of their time is actually taken up by processing and
dealing with parts not yet needed by the next step, or waiting or searching for the parts
they do need. When processes work on only what is immediately needed down the line,
large amounts of effort, lead time, and space requirements disappear.

Today's Limits to Continuous Flow


Ideally you would have a continuous flow from the beginning to the end of your value
streams. But the extent of continuous flow in our factories today is usually limited by
some of the existing equipment:

• Some equipment cycles faster than the customer demand rate, requires large invest-
ment, and must change over between different component types (e.g., stamping).

• Some equipment is too unreliable to couple directly to other processes.

• Some equipment cannot cycle fast enough to meet the shortest anticipated takt time
during regular working time (eg: injection molding, casting).

• Some equipment, such as for heating, painting, and plating is designed to process batches.

To date no one has been able to entirely eliminate the need to produce some batches
ahead of time in certain places. But through continuous improvement, creative utilization
of existing equipment, and development of simple, reliable equipment that can be dedicated
to product families, lean systems are getting closer every day.

102 Creating Continuous Flow


Needed units Hand
Standardized Work From: Get SS tube (raw) Date: April 12, 2001 per shift: 690
~Walk
Combination Table To: Place finished line to container Area: Truck Cell Takt Time: 40 s ---------- Auto

' Time (sec)


Work Elements Seconds 2x Takt
hand auto walk
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85

1 Get SS tube & place to bender 3 ----- I_____


--1- -----
1
2 Get bent tube & place to Assembly I 3 ~ '-
- I '
I
3 Get connector, place & clamp 4 - Ln
'
4 Get hose & place 4 - IL
5 Start Assembly I cycle 1 _ , ·z_----
1 <.._
6 Get finished piece & attach convolute 6 -
I
7 Place to Assembly li fixture 5 - L
I 11 I
8 Get hose & LH ferrule, assemble 4 ,____ L
n
9 Place to fixture & clamp 3 ,____ L
,____
I
10 Get RH ferrule & assemble to hose 3
I
11 Place & clamp 3 ,____
Ll
12 Get valve & place to fixture 3 ,____
~
13 Start Assembly li cycle 1 ,..._ l ----- --
1
14 Get finished piece, place RH side to fixture 5 - L_
(and so on) -
Waiting
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
Totals
Seconds

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