What’s One Piece Flow?
- One Piece Flow is moving one workpiece at a time between a work station within a cell or shop.
- In contrary conditions, we might reuse an entire batch or lot at each station before moving it to the coming station.
- In simple language, it means that the corridor 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 outfit is located within a cell in the sequence in which it’s used. It’s a veritably popular Spare Manufacturing Tool.
Is one piece flow or cellular flow always remains one piece in product?
- It isn’t necessary that it always remains one piece but in an ideal system, it remains one piece flow.
- It should fit the size of one piece to our capabilities as enforced in our installation.
- If our machine can produce six rudiments in a single operation, also it’s egregious that I won’t produce only one.
- Let we can produce six rudiments in a single operation.
So we’ve to take less frequently corridor/ products that are possible
Batch Product Flow vs One Piece Flow
- We can fluently understand the comparison between batch product and the single product inflow is mentioned in the below picture.
Conditions for successfully implementing Single Piece Flow
- The processes must be suitable to constantly produce a good product.
- If there are numerous quality issues also this spare tool can not be enforced
- The processing time must be unremarkable, if there’s much further variation in processing also we can not apply.
- The outfit must have a veritably high uptime (near 100) which means the outfit must always be available to run at any time.
- OEE ( Overall Outfit Effectiveness) increases by this.
- Processes must be suitable to match with takt time or fulfill the rate of client demand.
- For illustration, if takt time is 30 seconds also our processes should be suitable to produce a product lower than 30 seconds.
Benefits of one piece flow or benefit of cellular flow
It improves Quality and reduces blights in manufacturing and also reduces force and other Spare Manufacturing Wastes.
- It improves the morale of all hand and enhances overall manufacturing inflexibility
- By this, we can get a benefit to enforcing Spare Manufacturing in a plant.
- It fluently identifies the kaizen or enhancement
- It provides a safer work terrain
- Nonstop inflow Requires lower space
- It keeps WIP at the smallest possible position and encourages work balance.
Seven way to creating Single piece inflow
- Decide the Products
- Calculate Takt Time
- Determine the Cycle Time
- Outfit can meet Takt Time or not
- Produce a spare layout
- Determine the number of the driver is needed
- Balance the work between drivers
Decide the Products
- Decide which products or product families will go for product into your working station or cells, and determine the type of working station or cell.
Calculate Takt Time
- Takt Time = Available working- time per shift/ Client demand per shift
- Ex Work time/ Shift = seconds
- Demand/ Shift = 900 units
- Takt Time = / 900 = 30 sec.
- The client’s demand for 1 unit every 30 seconds.
Determine Cycle Time
- Determine the needed work rudiments, coffers and time needed for making 1 Nos. ( i.e. determine the cycle time).
Outfit can meet Takt Time or not
- In this step, we’ve to determine if your outfit can meet takt time or not
- The client’s demand for 1 unit is every 30 seconds.
- So, our installation is suitable to produce 1 good part in lower than 30 seconds.
- Insure that our cycle time must less than takt time.
Produce a spare layout
- You can choose any of the below layouts which is suitable for your process.
- U-shaped layout-the stylish layout or S- shaped layout
Determine the number of the driver is needed
- Determine the number of the driver is needed to meet client demand.
- Decide the optimum size of the drivers.
Balance the work between drivers
- Find our the tailback processes and balance the work between drivers.
- Balancing gives us a smooth product.
Some Common Reasons for Single Piece Flow Failure
- If we ca n’t get accoutrements in quality, in volume or in time.
- An unanticipated breakdown causes downstream processes to run out of corridor.
- Our people won’t borrow this change.
- In general, our people aren’t cross-trained for multitasking.
- The long transfiguration period fails this tool.
- There’s too important distance between the process way.
- The process produces blights that will stop the line if we’ve no buffer.
- Variable process cycle times produce an imbalance between workers.
- If our machines aren’t designed as per this spare tool.
- Occasionally our occasional work interrupts the process.
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