Lab 01

Evaluating the Impact of Replacing the One Piece Flow Assembly Line with
Traditional Batch Production
Course title: Operations of Manufacturing Systems

Course teacher/Lab Instructor: Dr. Muhammad Sajid

Student Name: __________________________

Registration no.__________________________

Marks Evaluation Sheet

Knowledge components Domain Contribution Max. Obtained
Taxonomy level
marks marks

1. Student has conducted the experiment by Psychomotor Manipulate (P2) 50% 5

practicing the hands-on skills
2. Student has followed the safety instructions and
Respond (A2) 3
time constraints while performing the Affective 30%
experiment
3. Student has analyzed and compared the results Cognitive Analyze (C4) 20% 2

Total 10

Normalize
marks out of 5
(5)

Signed by Course teacher/ Lab Instructor

 Lab 01
Evaluating the Impact of Replacing the One Piece Flow Assembly Line with
Traditional Batch Production
Objective
 To understand what is Batch Production?
 To understand what is meant by one-piece flow?
 To understand the working of traditional batch production assembly line.
 To understand the working of one-piece flow assembly line.
 To evaluate the impact of replacing the one-piece flow assembly line with traditional
batch production line on cycle time, Production rate, and Quality Efficiency.
Apparatus
 Assembly /Disassembly parts (5)
 Wooden Buckets
 Screw Driver
 Wrench
 Stop Watch
 Camera
Theory

In the manufacturing industry, companies aim to manufacture products that their customers need,
deliver them when they need them, quickly, cost-effectively, and using the smallest amount of
resources possible. Companies also want to avoid unnecessary intermediate storage that ties up
their capital. When it comes to determining their manufacturing system, two systems come to
mind: batch production and one-piece flow manufacturing.

Batch Production

Batch production is a method of manufacturing whereby a group of identical products are

produced simultaneously (rather than one at a time). It is up to the manufacturer to decide how
big the batch will be, and how often these batches will be made. Each batch goes through the
separate stages of the manufacturing process together. Meaning that another batch can’t begin a
stage, if the previous one is still within that part of the cycle.

Each batch can be different, as manufacturers can decide to change the specifications from one
group of products to the next. Perhaps it is necessary to change the color or size of that particular
group (depending on the preferences specified in a particular order).  

Major Features
  Can be suitable for growing SMEs
 A flexible method of production
 Each batch goes through all stages of production together
 Quality control can be carried out between batches
 Good for maintaining sensible levels of inventory
 Can be lots of downtime between batches

One Piece Flow

One-piece flow, sometimes called continuous flow or single-piece flow, is a

production method used instead of traditional mass production. In one-piece flow manufacturing,
workstations are arranged so that products can flow one at a time through each step of the
process. There is no downtime between steps. The following figure 1 shows the difference
between One-piece flow and Batch Flow production lines.

One Piece Flow

Batch Flow

Figure 1. One-Piece and Batch Flow Assembly Line

Advantages of One-Piece Flow
 Reduced Inventory
 Improved lead time for products to reach the customers
 A safer process, due to an optimized layout and less clutter in their work space. With
fewer touches comes a reduction in work-related injuries.
 Improved Quality and a reduction in defects
 More flexibility in less time
Cycle Time
Cycle time is the time it takes to complete the production of one unit from start to
finish. It is based on work process. If in an assembly line, there are more than one station, then
cycle time of a product will be the time that the product consumes at one station (Time to
complete part i at station i)
 Cycle time = Net Production Time / No of units produced
Production Rate
It is the fraction of parts produced during the lead time.

Utilization = Total Parts Made / Cycle Time

Quality Efficiency
It is the fraction of jobs that go through line with no defects on first pass.

Quality Efficiency = Number of non-defective parts / Total parts produced

Instructions
Follow these instructions to perform the tasks comprehensively:
 The part to be made is Bike Prototype as shown in figure below.

 First disassemble the given parts

 Perform all the assembly operations (one operation at each station) using Batch
Production and One-Piece Flow approaches.
 The layout of the stations will be same for both methods of production.
 You have to made total of 5 assemblies as per instructions
 The warehouse in charge is responsible to provide all material at workstations.
 Quality inspector will inspect either part is defective or not.
 For batch production, the whole lot of 5 assemblies must be moved together from one
station to the next.
 For One-piece flow, one assembly will (work in process) will move from all stations until
the end product is achieved (Figure 1).
 This lab is based on team work. Understand your role in the team and perform
accordingly.
  All human resources must be utilized effectively to perform the task.
 It is suggested that at least two students make the video of the task. The videos must
capture the activity of each worker throughout the production cycle.
 Critically analyze the videos to answer the questions under ‘results and discussion’.
 Take care of your own safety and safety of others.
 Complete the task within the time allowed.
 Clean the workstation and arrange the tools and equipment after performing the task.
 Do not leave the lab after performing the task without permission of the lab in charge.

Results and Discussion

Calculate the Cycle Time, Utilization, Quality Efficiency
Stations Cycle time (Mint/part) Production Rate Quality Efficiency (%)
(Parts/mint)
Batch One-piece Batch One-piece Batch One-piece
1
2
3
4
5
6
7
8
Total
%Improvement

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