Lean Manufacturing One Piece Flow vs. Mass Production Paper Airplane Simulation (Lean Tip 005)
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- Опубликовано: 16 июл 2024
- See how to transform slow and wasteful mass production into lean one piece flow in this simple and fun paper airplane simulation.
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Thank you for watching - I really appreciate it :)
Cheers,
Daniel | Lean Smarts
Neat video editing, the handover moment looks pretty smooth. Also, neat explanation of one-piece flow, thanks for sharing!
I'm glad to find your demonstration clip on production systems. This is the best practical explanation with great editing ever! What an effort! Thank you for your time! I really noticed each n every part of the process. 🙏😩
Thanks Daniel, that's the best explaination I've seen online so far, and I think there won't be a more fantastic video than yours
it's an simple and amazing example to understand one piece flow!!!
Great Explication... Thanks for this video
01:04 First Process
01:46 Start First flow
05:10 Start second flow
Simple but straight to the points of saving
Great demonstration. Direct, concise, interesting.
Well said!! 👍 great simple explanation.
best example guys. Clear my doubts. Thanks
Wonderful i will effect this in my garment production
thanks for sharing. awsome explanation.
Hola
Tu explicación fue mucho más clara que la que me enseñaron en un taller de 4 HORAS.
Muchas gracias.
Greatly and simply explained
Good job ..nailed it
nice video, thank you for the shared of
knowledge
Nice explanation with excellent and simple ideas
FANTASTIC demo of 1 piece flow. Great job and very funny. great editing. I love your evil twin brother :P keep it up
Great video. Thank you
Thank you for this brilliant video.
Thank you An nguyễn!!
Great example!
Excellent! very well explained. Thanks for sharing
Thank you so much!!!
Simple example but an eye opener!
John Frontier thank you!
amazing
thanks
This is an awesome and effortless explanation. Thank you so much, Daniel. It is the best explanation I have seen online so far.
Awesome, OluwaKemi! So glad to hear that!
Fabulous explaination
Good simulation
Thanks!
One peeve I have with this type of example (here and other places I've seen similar ones) is that most of the improvement comes from making station 2 work at the time as station 1 as opposed to sitting around waiting. In real life, you're probably going to be continuously doing batches of 5, in which case (after the very first batch) both stations are already going to be working simultaneously. In that case, there can be benefit to one piece flow, but not necessarily... you have to take into account set up time and the like.
Hi John! The video primarily demonstrates significant lead time improvement. There’s also a reduction in process time per airplane due to some reduction of motion. But even *if* there is no change in the amount of process time per airplane, the lead time reduction is very beneficial for the nimbleness of an operation and its ability to adapt quickly to changing customer demand or production problems. Perhaps one day we’ll make a new one of these videos that more strongly demonstrates process time improvements! In the meantime, don’t throw out the idea of flow. There’s radical gains to be achieved by it.
Sure, but it's about finding the right sized order for the flow to continue. In that example, it made sense to the workflow to do 1 at a time then pass it off.
In my company, we recently discovered that small batches work well in certain situations. For example, we have a customer who put in an order for 10 different items... each item had several components with slight variations, so it requires double checking. So instead of one person processing the whole order at once then handing the whole order to someone else to check, they discovered that if they hand off one item at a time the end result is the whole order being input and checked in less time.
So, yes, some flows required small batches of work for it to keep flowing smoothly through the system. It's really about the flow of the process.
On the extreme other side of my example, my workers could have input 1 line item then had someone check it. Then one more line item then had someone check it, but that was way too much going back and forth causing a lot overprocessing and transportation that isn't needed.
thanks for your sharing on video
I'm jealous of his brows.
So was everyone else in high school. Except they used different words ;)
This was wonderful!
Thank you Angel!
No u
This video - and many similar - aims to illustrate the 'large' benefits of reducing batch sizes. It primarily illustrates is the effect of idling resources; resources in the batch process are idle half of the time. In a continuous flow, the throughputs are identical and independent of the batch sizes, i.e. the productivity is identical. The benefits of reducing batch size come from the reduced WIP and/or cycle time. And then we are back to the discussion of the trade-off between transaction costs and holding costs - or efficiency versus speed
100%!
Nice presentation 👍
Hi Daniel what a fantastic video!! It’s the best video I’ve ever seen showing the difference between batch work and one piece flow. Great Job!! Take care, Filipe
Thanks Filipe! I really appreciate that! You rock.
Very nice
Thanks
Nice
I work as a welder, and this technique works on some of the products, but not all of them.
Would there also be an improvement if the 1st and 2nd department make 2 each at the same time(4) and the the remaining (1) by either or?
Do you have a version of this video in spanish and french?
In this example, you can eliminate the idle time of the workers entirely by letting both of them do the entire process separately from one another. Also, it looks like you could do the first three folds with the entire batch of 5 stacked on top of one another. One more thing worth considering is that you can do folds 2 and 3 simultaneously with your left and right hand. Perhaps a "press" of some sort would also help speed up the process of carving out the lines in the paper, much like Japanese printmakers do, albeit in a different way, with special wooden tools. Interesting example!
so what's the 3 :54 record from? old method or new method?
I'm convinced this man has a twin.
So does it ever make sense to batch, and if so when?
but what if we have a good planning so instead of waiting for the inventory from the step before, they work on another product for instance so we keep production by batch but no dead time?
In a realistic production situation there would have been approx. twice as much produced in the batch scenario, as in the video both workers were idle for around half the time. Normally they would have been finishing the previous batch or starting the next.The time saving is in the elimination of picking up and putting down the paper, so it's a lot less than the video shows on face value but still worthwhile.
Josh C Incorrect because in a realistic production situation you would look at tac times and utilisation which would result in less indirect time and reducing wip.
You are correct! I was thinking the same thing.
Given some love here, process engineer in training with this thought
What a simple explanation! It’s really intelligibly. Go on!
Crucial part of course is to identify waste. Are we mainly talking about time factor and stuff/inventory not in the right place? What are other waste? I work in IT, and always try to find best practice or procedures after testing the process over time. This concept can be applied anything which is great.
I agree James, lean can apply anywhere!
Very interesting video !
But if there is only 1 batch to produce, this video is ok but in real production, when department 1 is producing batch N, department 2 is not waiting but finishing to produce batch N-1.
Then when dept 2 is finishing batch N, dept 1 is starting ton produce batch N+1.
That would be interesting to explain that for batch production : they finish 2 batches within 4min59, batch N-1 then batch N (so 29,9 sec/pcs),
then with one piece flow : they finish 1 + 5 pieces within 1min47 (so 17,8sec/pcs).
So -41% process time / pcs
Lean is the way \o/
you need to add buffer inventory at key places to ensure the work is balanced. in this example each 4 operations basically took the same time for each employee but when they are drastically different you need to add more workers to the slower process or add more buffer inventory in between stations
For the company I worked for a blend of old vs new processes was ideal, one piece flow doesn't work great when you have multiple workstation processes, you lose time getting up and moving to next station. Per.piece it's slower than perhaps doing 5 pieces moving to next station making the next move with those 5 pieces, just be cognizant of an employee at the end stage is not waiting , it an adaptive process , what works for one company might not be ideal for another. It's a continuous improvement process.
what was the value?
There was so much muda in the second run, Toyoda had a stroke watching this.
What about if both employees folded the entire airplane by themselves? It would eliminate the transfer time between work cells and the idling of the second cell while waiting for the part assembly. Is there only one type of paper airplane ordered and are they all in A4? Not even talking about the differences between the manufacture times between cells if few types of the planes require different more or less intricate folding patterns! The folding process also doesn't seem all that optimized but I'll let that slide as this is just a demonstration.
As far as I can see after quite a significant time of research into it, one piece flow is an exellent option for departments that manufacture a specific device or appliance but when said department is working in a niche market, manufacturing specialized unique devices in small batches there is no way that one piece flow will work. There is too much variation in the processing times of the said units depending on the size and complexity of the devices we manufacture that the production line grinds to a halt every time waiting for diferent cells to slowly dribble the units up the manufacture chain.. Yet the bosses praise the religion of the one piece flow. It sure works but also has some definite exeptions which should be brought up more instead of making it be the miracle solve-it-all that it theoretically seems to be.
I absolutely despise coming to work just to kill time for 8 hours before going back home to try again the next day. Wasted potential at it's finest.
Agreed with you. I got 40years of experience in garment manufacturing. Lean method does not apply to every designs of apparel. Complicated garments like cargo shorts or pants has over 50 compnents in average which required whole different set of machines and complex operations. Lean doesnt work on such complicated garments. Apparel that has less than 20 operation are practical in lean manufacturing.
One piece flow does not meant sub-assemies aren't produced in batches.
One piece flow generally applies to a final assembly line.
Well comparaison is kind of wrong: you are only considering 1 batch of five making the two employees doing nothing for more than two minutes.
If you consider several batches, you're bottleneck will be on step 2 (2:45 minutes). So it takes you 2:45 minutes to make 5 pieces (not 4:59). Improvement is still 35%, which is great
Don't you have 5x the transportation with the one piece flow? How does that figure in?
No. Since it is a one-piece flow, it will flow in the production line in the quickest and smoothest way. Whereas with overproduction, you will need to store ( larger space) and need conventional transporting system ( trucks etc).
I made a polish subtitles for this video and i can share it with u if u want. :)
Nicely explained...
But it can be presented by using simulation software by assuming real data from any industry?
Please, suggest us
Hi Chetan - are you asking for a simulation software? I'm not familiar with many, although I bet there's something out there. However, a lot can be accomplished in Excel if you wanted to determine the theoretical output of different systems!
Yes, I am working on SIMUL8, the issue that I am facing is the industry data for any single component such as.....
the monthly requirement, no. of operations, and processing time, etc.
Can you suggest , how can I get this data, so that my simulation will be more practical.
I really appreciate your videos. You are giving great examples to learn about Lean. But I have a doubt regarding one comment that you did. It’s about Inventory. For me, inventory is the action to count what do you really have in your process or factory because somehow you don’t trust the accounting system that you have.
And of course it is a total waste. But I don’t see that you are counting planes in your video. But of course you could do it, and yes it will be. Sorry to share my thoughts
Don’t apologize! I think I understand you, and in a way I don’t disagree. But I would instead say that the “gemba” is the truth. That’s the Japanese word for the actual place where work is performed. A good and smart manager or person will go to the gemba to know the real situation. Computers and reports are powerful and can be useful, but there’s no substitute for the real place. Also, there’s often error between the gemba and softwares/reports. At the end of the day, the accounting records need to be completed and hopefully accurate. It’s easier if there is less inventory. But it’s still a necessary evil to audit and cycle count, etc.
@@LeanSmarts 👍👍 I agree totally. Gemba is the truth, what it is really happening. I’ve heard that in some places they are calling the 9th Muda the Wrong information. Some how if the information that you have is not correct you will need to check or look for the correct one. (In my opinion that will be included in the inventory Muda). Many thanks for your reply!!
THE ONE PIECE
😍
Stack the 5 pieces of paper and do the folds all at once with just one person. Quality may be worst. Break up into small groups of paper for improved quality, like 2 pieces
Haha talk about trying to sell yourself. Interesting video though thanks for sharing.
Are we sure that the 64% in improvement is the correct number? ;-)
yes... ;)
This video does not prove that the batch processing is slower (which, in fact, is faster). It only proves that badly organized process is slower and wasteful.
batch production vs. one each flow ...
So that's what Toyota and Nissan does
Balincing of work stations.
all of a sadden you see that you need to transport it 5 times.
I like your videos but in the spirit of helping you I have to say this one is totally invalid. There are strong advantages to batching (like reduction in setup time, operators muscle memory, familiarization with expected quality standards, not having to get re-acquainted with pertinent procedures, to name a few) If you had operator A and B both working simultaneously on different folds, and doing a meaningful number like 100 units you get a different result. Our factory improved production throughput by 40% by moving from continuous flow to BATCH production.
Congratulations on improving your throughout by so much! That’s quite a large improvement in that metric. Unfortunately, I’m not familiar with your factory. I’m familiar with other factories though that have converted batch production to one piece flow and seen immediate 95% or more reduction in lead time. That’s more my frame of reference in this highly conceptualized video. Best regards, Daniel
Agree. I think most of the waste in this video comes from the under-utilization of the resources. Only one of the two resources are working. Startups and shutdowns should not be included in performance measures - and are explicitly NOT covered by e.g. Little’s Law. If you do this exercise on 100 batches and don’t count the first and last, you will get a completely different result. And there ARE benefits in batch production, typically that it distribute startup costs over several items or by handling all items at the same time (economics of scale).
Erik Kaare Andersen that's a very good point. I work in aerospace and we use lean manufacturing. But we also machine in batches. However we utilise single flow within batches. For example a component will be ground, then go on EDM and then go on deep hole drill rather than grinding all 100. Then EDM 100 then deep hole drill 100 this is still classed as a batch, but also single flow. Make sense? I like this video amd im going to share at work to show new starters the ideology of lean and waste reduction TIMPWOOD 😃👍
@@erikkaareandersen9922 The waste here is waiting time ( 1 out of 7 wastes)
One piece😁
Who cares about LEAN, what I want to know is how you invented cloning!
Everything I've seen when it comes to "Lean" seems to come down to the advice of "don't work stupidly", such as not working while you wait for someone. Another advice is to "eliminate unnessesary processes", like if you are producing a car, don't spend time climbing a tree. I honestly don't get what lean is contributing with. It also has no acknowledgement of tradeoffs. In lean "inventory is just bad".
Inventory is bad, until you get a huge order, or materials become scarce 🤣
I look lean six sigma in marine corps and honestly this example sucks. You need to have the batch team produce 50 and the JIT team make 50. JIT would of course be faster because there are less pickups, but there’s still more passes to the next department. You you wouldnt normally have a batch team not doing shit for half the production time. Maybe a 30% reduction not 80%. I understand it’s an example, but cover more angles so people understand it’s not BS. When I took the class the examples were kind of like this but as an investor you see it more realistically.
Any scmpe students😂?
This is a horrible example
I hate lean and it doesn't work and reduces quality. Awful model.
Its an already pretty well established methodology. Maybe youre implementing it wrong
Example in the video is awful.
You had two guys working at the same time last time🤔🫠 Would like to see how long one guy could do it completely from start to finish. For a complex build with with different skill sets needed it would be more difficult to do it quickly and maintain quality.