OneDay Flow, sometimes called continuous flow or single-piece flow, is a production method used instead of traditional mass production. In mass production, materials move through the manufacturing process in batches which can be highly inefficient. In OneDay Flow, a product is completed before the next one is started typically used in Lean organizations and will help businesses achieve the just in time production.
Simply speaking, OneDay Flow means parts are moved through the facility with little or no waiting time and arts are moved though operations efficiently. While this method of production may not seem intuitive, it is actually faster than performing Step 1 of a process on 100 products at once before moving on to Step 2. In mass production, it takes time to switch tasks or move products as a group. OneDay Flow is generally more efficient, limits the amount of work in process, and prevents bottlenecks. The concept of OneDay Flow is to only process and produce what the customer wants, effectively working to reduce the risk of excess production.
Setting up a workplace for OneDay Flow production can require some planning and rearranging of workstations. Each step in the process should be placed next to the subsequent step to reduce motion and machines are placed in a logical order according to the production process. A Lean layout uses the principles of 5S to create a workspace that is easy to work in and follows the steps of productions. Takt time should be calculated to ensure cycle times are less than or equal to the takt time, and if a pull system is not already being utilized, it should be introduced into the workplace.
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