The term One Piece Flow or Single Piece Flow indicates items proceed through the various stages of production one «piece at a time».
In companies that start to adopt the Lean paradigm, gradually, they move from an organized production in batches (push), typical of the production philosophy of mass production or traditional production, to a pulled-flow production (pull)Kanban.
Batch processing or traditional production usually isn’t efficient, the customer usually has to wait until the next batches produced to get their required product. The processes designed in Just in time methodology and cellular manufacturing uses one piece flow.
The Lean philosophy aims to minimize stocks, including inter-operational ones, because they hide the problems, both related to the machinery (16 losses), and related to labor (not respected standard cycles, imbalances in activities between different operators). To produce one piece at a time means to have optimized the whole production process, from the first to the last phase. (Kanban(pull), Just In Time methodology, Cellular Manufacturing and 16 losses – see these terms in the glossary)
Advantages of one-piece flow:
- Increase value addition to product and decrease non value added activities.
- Eliminates Over Productions and enables production on-demand
- Reduce inventory by eliminating huge raw material requirement, WIP stock pile between the processes and finished goods as it was pulled against customer demand.
- Movements of people and transportation of goods decrease drastically due to pull system.
- Maximize floor space utilization.
- Easy defects identification and segregation.
- More safer environment due to optimized layout.
- Reduced Lead times
- Ergonomically efficient for operator can work more efficiently with lesser fatigue.
One Piece Flow or Single Piece according to Lean philosophy is a very good tool to remove Muda (無駄, waste), Mura (斑, unevenness), and Muri (無理, overburden) – see these terms in the glossary.
One piece flow makes the production process flow continuous and smooth, single piece at a time, creating a steady workload for all operations.
One Piece flow requires:
- Working Kanban (Pull) system
- Cycle times must be repeatable and in sync or scaled to TAKT Time.
- Equipment used must have higher uptime
- Shorter changeover times
- Processes must be able to consistently produce a good product
TLDR
- One Piece Flow is a production method where items proceed through stages one piece at a time.
- It's a key component of the Lean paradigm, moving from batch production to pull-flow production.
- One Piece Flow aims to minimize stocks, optimize production processes, and eliminate waste.
- Advantages include increased value addition, reduced inventory, and improved floor space utilization.
- It also enables defects identification, creates a safer environment, and reduces lead times.
- One Piece Flow requires a working Kanban system, repeatable cycle times, and consistent equipment uptime.
FAQ
What is One Piece Flow?
One Piece Flow is a production method where items proceed through stages one piece at a time.
What is the main goal of One Piece Flow?
The main goal of One Piece Flow is to minimize stocks, optimize production processes, and eliminate waste.
How does One Piece Flow differ from batch production?
One Piece Flow is a pull-flow production method, whereas batch production is a push-based production method.
What are the advantages of One Piece Flow?
The advantages of One Piece Flow include increased value addition, reduced inventory, improved floor space utilization, defects identification, a safer environment, and reduced lead times.
What are the requirements for implementing One Piece Flow?
The requirements for implementing One Piece Flow include a working Kanban system, repeatable cycle times, and consistent equipment uptime.
What are the benefits of One Piece Flow for operators?
The benefits of One Piece Flow for operators include ergonomic efficiency, reduced fatigue, and a more steady workload.
