Professional Documents
Culture Documents
Single
Piece Flow)
for Lean Manufacturing
Page Contents
What is it
How Does it Work
Resources Required
Symptoms indicating that it is needed
Example/Case Study
1. What is it?
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 customer’s order.
a. Batch sizes are recorded for historical system (baseline).
b. Optimum batch size and transfer sizes are calculated, starting with:
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 include:
i. SMED
ii. Kanban
iii. Process re-design
iv. Production sequence
v. JIT
vi. Etc.
3. Resources Required
a. Process Map
b. Calculator
c. Process comprehension
d. Value mapping
a. Long delivery lead times (customers will consider paying more to defeat them)
b. Obsolete inventories
c. Large batches of defects & rework, all with the same or similar defect.
f. Slow changeovers
5. Example/Case Study
Penny Lane Game
1 Start 2 3 4 5 6 7 Done
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