a. Single piece flow is the ideal state where parts are
manufactured one at a time, and flow throughout the manufacturing and supply
chain as single unit, transferred as customerís order.
b. Manufacturing large batches of parts simultaneously,
or accumulating parts in a bin for shipping or transferring 2 or more parts
at the same time is opposite or contrasted to the definition of Single Piece
c. Single Piece Flow (SPF) supports Just-in-Time, Toyota
Production Systems, Lean Manufacturing, Theory of Constraints (Drum, Buffer,
Rope), and similar types of philosophies and systems
Does it Work ?
sizes are recorded for historical system (baseline).
b. Optimum batch size and transfer sizes are calculated,
most critical work centres
ii. The largest inventory carrying costs
iii. The highest risk processes
iv. The most unpredictable process
v. Other controlling factors
c. Action is taken for improvement at the work centres,
rules, methods that have the greatest impact on the throughput, customer
satisfaction, risk, cost, or inventory carrying charges. These actions can
iii. Process re-design
iv. Production sequence
a. Process Map
c. Process comprehension
e. Authority to make process improvements
f. Process operating date (ie. flows, batch sizes,
indicating that it is needed
delivery lead times (customers will consider paying more to defeat them)
b. Obsolete inventories
batches of defects & rework, all with the same or similar defect.
product velocity ratios (3 is excellent, 60 is poor)
inventory turns (100 is excellent, 3 is poor)
at beginning & end of production run