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.

Norman Bodek
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.