Flow is an important concept in Lean Manufacturing. Traditional manufacturing of products were produced in the exact opposite of the Flow discipline. Products were made in large batches and passed from one process to the next until finally reaching the customer.

Ideal Lean Flow is where one product is produced at a time, and “flows” through the system.

Although some industries and their associated machinery are not conducive to “one piece flow”, adaptations to enable a continuous flow can be designed.

Some process industries have not adopted lean manufacturing principles because of their belief that lean is based solely on one piece flow. However, even if process industries, lean manufacturing flow techniques can be employed to minimize waste. For example, in industries with machinery producing 200 pieces per minute with 45 minute setup times could not possibly produce one piece at a time. However, the secondary machine center could be running the first piece within seconds after it is produced on the first machine. This method of production would spot a defect from the first machine immediately. Also, in time applying lean principles to the process may reduce the setup time to single digit minutes thereby reducing the quantities and lead times necessary for the company to produce.

Set up times are critical in the flow discipline of lean manufacturing. There are many examples of machinery that once took hours to set up that now take minutes.

Flow has many other applications in lean manufacturing. It is important for product to continuously flow through the plant. If product is stopped, it is increasing the company’s work in process, increasing working capital, taking up floor space, and causing other flow inefficiencies.

BPR’s lean manufacturing certification online courses can be completed at your convenience 24/7. Simply log in and begin the course. You can stop any time and come back to where you left off. Once the course is successfully completed, the certification will be mailed to you.