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1、What does the ideal line design accomplish?Lets find out by doing theFlow Game!Exercise 1The objective is to transfer all four balls through the team as a batchRules:1.Each person must stand on pre-determined location.2.No one is allowed to help.3.You must use hands only to catch and throw balls - n
2、othing else.4.All four balls must be in the air at the SAME TIME!EXERCISE # 11Exercise 2The objective is to transfer all four balls one at time but holding until batch quantity is metRules:1.Each person must stand on pre-determined location.2.No one is allowed to help.3.You must use hands only to ca
3、tch and throw balls - nothing else.4.Only one ball in the air at a time.5.You may only throw after catching all four balls. You cannot throw if the person receiving does not have all of the previously thrown balls.6.You cannot throw until all four balls have been transferred.EXERCISE # 21YOU CAN NOT
4、 THROW A BALL UNTIL YOU RECEIVE ALL 4 BALLSExercise 3The objective is to transfer all four balls one at timeRules:1.Each person must stand on pre-determined location.2.No one is allowed to help.3.You must use hands only to catch and throw balls - nothing else.4.You may throw the ball as soon as you
5、can, provided the receiving person does not have possession of a ball AND has passed on their ball.EXERCISE # 31BALLS CAN BE PASSEDAS SOON AS NEXT PERSON IS READY FOR ITExercise 4The objective is to transfer all four balls as fast as possible with no constraintsRules:1.Each person can stand wherever
6、 they want.2.No one outside the group is allowed to help.3.Each person MUST touch each ball.4.Clock stops when the anchor person yells “STOP.”What did we learnfrom the Flow Game?Ideal DesignOP1OP2OP3OP4One Piece FlowEvery operation is connectedWhen an operation consumes one partthe previous operatio
7、n replenishes that partOP1OP2OP3OP4Why One Piece Flow?In a batch process, all parts are sent downstream together.If an error is created in Op1 and found in Op4, ALL parts are then rejected. X X X X X X X X X X X X X X X X X X X X 20 pcs. made X X X X X X X X X X X X X X X X X X X X 20 pcs. Batch Pro
8、cessX X X X X X X X X X X X X X X X X X X X20 pcs. X X X X X X X X X X X X X X X X X X X X20 pcs. 80 parts total rejectedOP1OP2OP3OP4One Piece FlowIn a flow process, only one part at a time is sent downstream.The maximum reject quantity is one piece times the number of operations.X4 pcs. made so far
9、.X 4 pcs.total rejectedXXNo overproduction.Using pull systems that connect all islands of production from end to end saves space.Arranging production equipment in the order that employees work instead of grouping them by equipment function continuous flow.ConclusionConclusion - I - IQuality issues found immediately less defects.Reducing lot sizes to one piece leads to production flexibility and shorter lead times.Pulling production through the process at a rate equal to the rate of sales meeting customer demand.ConclusionConclusion - II - IIThank you for your time!
