Batch vs One Piece Flow Manufacturing

Batch production vs. one-piece flow production is explained in this video. Companies that want to implement lean manufacturing cannot fail to know the difference between these 2 different ways of interpreting the production of goods and services.



📹 Related Video

▶ What is Just In Time
https://www.youtube.com/watch?v=OXVi7dOF3jU

▶ Lean Principles and Lean Tools
https://www.youtube.com/watch?v=TkMbhhfpras



✏️ Here is the transcript of the video

The Batch and Queue approach is a method of mass production where large quantities of items are processed in batches and then moved on to the next stage of the production process, regardless of whether they are actually needed or not.

These batches then form queues or lines, waiting to be processed further.



▶ Car Manufacturing Example with Batch and Queue

Let me give you an example.

Imagine a car manufacturing plant.

The plant produces a large number of cars, and the assembly line is designed to work on one car at a time.

With the Batch and Queue approach, a batch of cars would be produced first, and then they would be moved to the assembly line regardless of whether all the parts were ready.

This creates a queue of cars waiting to be assembled.

As a result, some cars may be waiting for a long time before they are actually assembled, while others are moving through the production process at a much faster pace.

The problem with this approach is that it creates a lot of waste. Waiting time, transportation, inventory costs, and other wastes all contribute to inefficiencies in the production process.

This can lead to longer lead times, higher costs, and lower-quality products.



▶ One Piece Flow

So, what's the alternative?

The Lean Manufacturing approach is based on the idea of producing products only when they are needed, in the quantities that are needed, and with minimal waste.

This approach is also known as Just-in-Time production.

In Just-in-Time production, the focus is on reducing inventory and minimizing waste.

This means that products are produced in smaller quantities and only when they are needed.

This helps to reduce waiting times, transportation costs, and other forms of waste.

By producing products only when they are needed, Just-in-Time production helps to reduce the amount of inventory that needs to be stored.


▶ Conclusions

To sum up, the Batch and Queue approach is a mass production method that results in large quantities of items being processed in batches and forming queues.

While this approach may have worked in the past, it is not suitable for today's Lean Manufacturing practices.

The Lean approach is based on producing products only when they are needed, in the quantities that are needed, and with minimal waste.

So, if you're looking to optimize your production process, consider switching to Just-in-Time production.




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