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Training with Before and After pictures
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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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5 S IN B-VENT AREA-BEFORE
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BEFORE 5 S
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B-VENT AFTER 5-S
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B-VENT AFTER 5 S
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Process/Material Flow
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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
• 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
QUESTION ON CYCLE TIME
40 min
20 min 25 min
15 min
30 min
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5 4
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•What is the process cycle time? •What is the process bottleneck?
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
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10 min exercise on Batch and 1 Pc flow
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Next we set-up 1-pc flow in components
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