Flow production - 8th condition
From: Norman Bodek
The last is
Condition 8: To make the flow clean
Terms used by Mr. Hirano are:
"Turbulent flow" used for a job shop when each item produced
could be different.
Tidy flow used when products are produced in repetitive
manufacturing when the line is clean and items are produced without defects,
in takt time, in one-piece flow.
Muddy flow when parts are pushed forward from the preceding
process or defectives are produced.
Tidy, clean or smooth flow is when the succeeding process
pulls from the preceding process and a structure is created that prevents defectives from
being produced and surely never passed onto the succeeding process. Required are the first
seven conditions with machines fully synchronized, extensive TPM is being done to prevent
machine failures, poka-yoke devices are installed to absolutely prevent a defect from
occurring and people are highly skilled to run the equipment, with knowledge of the
requirements of production and have the ability to to be too difficult to do and use
larger lot sizes like a lot of ten pieces, there will be some waste within the ten pieces.
How thoroughly one-piece flow, can be maintained without a compromise is the
biggest key for a success of flow production.
I do hope you have found this series of interest.
Author of The Idea Generator - Quick and Easy Kaizen, Kaikaku The Power and Magic of Lean
(winner of the Shingo Prize) and All You Gotta Do Is Ask.