What is One Piece Flow?

Is one piece always remains one piece in production?

Batch Production Flow vs One Piece Flow:

Requirements for Successfully implementing Single Piece Flow:

Benefits:

Seven steps to creating Single piece flow:

Decide the Products Calculate Takt Time Determine the Cycle Time Equipment can meet Takt Time or not Create a lean layout Determine the number of the operator is required Balance the work between operators

Some Common Reasons for Single Piece Flow Failure:

→ One Piece Flow is moving one workpiece at a time between a work station within a cell or shop.→ In opposite conditions, we might process an entire batch or lot at each station before moving it to the next station.→ In simple language, it means that the parts are moved through operations from station to station with no work-in-process (WIP) at any station.→ This tool works best in combination with a cellular layout.→ In Cellular Layout, all necessary equipment is located within a cell in the sequence in which it is used.→ It is a very popular→ It is not necessary that it always remains one piece but in an ideal system, it remains one piece.→ The size of one piece should be fitted to our capabilities as implemented in our facility.→ If our machine can produce six elements in a single operation, then it is obvious that I won’t produce only one.→ Let we can produce six elements in a single operation.→ So we have to take less often parts/products that are possible.→ We can easily understand the comparison between batch production and the single product flow is mentioned in the below picture.→ The processes must be able to consistently produce a good product.→ If there are many quality issues then this lean tool cannot be implemented→ The processing time must be repeatable, if there is much more variation in processing then we can not implement.→ The equipment must have a very high uptime (near 100 %) which means the equipment must always be available to run at any time.increases by this.→ Processes must be able to match with takt time or fulfill the rate of customer demand.→ For example, if takt time is 30 seconds then our processes should be able to produce a product less than 30 seconds.→ It improves Quality and reduces defects in manufacturing and also reduces inventory and other→ It improves the morale of all employee and enhances overall manufacturing flexibility→ By this, we can get a benefit to implementingin a factory.→ It easily identifies the kaizen or improvement→ It provides a safer work environment→ Continuous flow Requires less space→ It keeps WIP at the lowest possible level and encourages work balance.[1] Decide the Products:→ Decide which products or product families will go for production into your working station or cells, and determine the type of working station or cell.[2] Calculate Takt Time:→ Takt Time = Available working-time per shift / Customer demand per shift→ Ex: Work time/Shift = 27,000 seconds→ Demand/Shift = 900 units→ Takt Time = 27,000/900 = 30 sec.→ The customer's demand for 1 unit every 30 seconds.[3] Determine Cycle Time:→ Determine the required work elements, resources and time required for making 1 Nos. (i.e. determine the cycle time).[4] Equipment can meet Takt Time or not:→ In this step, we have to determine if your equipment can meet takt time or not?→ The customer's demand for 1 unit is every 30 seconds.→ So, our facility is able to produce 1 good part in less than 30 seconds.→ Ensure that our cycle time must less than takt time.[5] Create a lean layout:→ You can choose any of the below layouts which is suitable for your process.→ U-shaped layout - the best layout or S-shaped layout[6] Determine the number of the operator is required:→ Determine the number of the operator is required to meet customer demand.→ Decide the optimum size of the operators.[7] Balance the work between operators:→ Find our the bottleneck processes and balance the work between operators.→ Balancing gives us a smooth production.→ If we can’t get materials in quality, in quantity or in time.→ An unexpected breakdown causes downstream processes to run out of parts.→ Our people will not adopt this change.→ In general, our people are not cross-trained for multitasking.→ The long changeover period fails this tool.→ There is too much distance between the process steps.→ The process produces defects that will stop the line if we have no buffer.→ Variable process cycle times create an imbalance between workers.→ If our machines are not designed as per this lean tool.→ Sometimes our occasional work interrupts the process.