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Learn what is one piece flow in manufacturing and how it can boost profitability and improve product quality by reducing cycle time and minimizing waste in production.
One piece flow, sometimes referred to as “continuous flow” or “single-piece flow,” is a discrete production method used in lean manufacturing that is closely associated with the Just-in-Time system—a key concept within the Toyota Production System. One piece flow is also one of the most important factors to consider when it comes to developing a lean environment.
The most efficient strategy for higher efficiency is to use one piece flow in combination with a cellular layout, wherein all necessary equipment is located in a single area during the cycle of operations. This is simply laying out or setting up all necessary materials or machineries according to the order of their workflow.
One piece flow is also closely related to discrete manufacturing. Discrete manufacturing is the production of distinct items like cars, furniture, electronics (e.g. smartphones and computers) and airplanes. Discrete means “individually separate and distinct,” implying that the product can have different characteristics or can be added with other features as demanded during the process.
There are a lot of sources and experiments where one piece flow is compared with the batch production process. Unlike in one piece flow where each item go one at a time through each step, batch production is a method wherein goods or items are produced by batch, in bulk, or en masse. The goods in batch production have to be finished first before it can be moved to another step. See illustration below:
Batch Production vs One-piece Production source:
When materials move through the manufacturing process in batches, it can be inefficient. There are additional steps which add to production time. In one piece flow, a product is completed first before beginning with the next item.
One piece flow has a number of major advantages compared to batch production flow, particularly in terms of waste reduction, manufacturing time reduction, and better process efficiencies. More about its advantages are listed below:
To execute a one piece flow effectively, companies need to have good supporting software or platform. One piece flow promotes
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