Batch vs. One-Piece Flow Production

Treston puts the one-piece flow principle to the test! See for yourself how it compares to batch production in our latest video.
Do you want to learn more about one-piece flow and lean production and how you can apply it in your company? Check out our blog: www.treston.us/blog/batch-vs-...

[@derrekholland5207]

Excellent video. Love the side by side comparison as it shows all the added motion in the batching process.

[@professorbnelson3592]

I appreciate that you are posting a clear process video to help people learn about flow optimization, and of course, we'd like to encourage single-piece flow, but this isn't really a fair comparison to demonstrate the reasons. This workspace is set up for single piece with only room for one box, limited packages, etc - so causes wasted motion when there are too many parts for the physical space. This process also requires no set-up (or the set-up is already done before the demo starts) so of course 1-pc works. There is no change-over to leverage over multiple pieces.

[@guss90]

Obs: the layout of the table is designed for one piece, not batch. Also, we will need to increase the sample to see at what point is convenient processing by pieces, or batch. Nice video, it helps to start talking about productivity and inventory, thanks.

[@JackBusseyUK]

Great video, thanks for sharing

[@hk811101]

Nice example!

[@GembaDocs]

Nice vid guys!

[@macmaniacal]

I'm out of room, table space so one piece flow works. It allows me to place tools closer to the work being done, which reduces other wastes.

[@flavioalberto3371]

como garante que trabalhou no mesmo ritmo nos dois casos? o layout é mais favorável para flow ou batch?

[@tbugduoduo4767]

但是要做到完美的一件流，需要做好精益，把物料工具即手可得，但是这个视频很棒！👍

[@myanis007]

nice video..but in terms of flow the one piece flow can be further improved by making the one straight flow.the box making process should be rearranged to be the last process..the rest remains the same

[@billbenedict4664]

The batch worker was slower because of the added steps of laying pieces out on the table, whereas the flow person simply put them into the envelopes. This makes the comparison a little unfair since one was given extra tasks of touching the parts multiple times for no reason. The batch person here should have had a competitive if not better time because of the reduced changeover steps.

[@ericyang736]

It's misleading and does not compare apples to apples. In batch mode, there are extra steps (00:36 - 1:26) that take 50 seconds, but do not exist in one piece flow. One piece flow finished at 2:23, while batch mode ended at 3:13 - exactly 50 seconds longer. So there's no difference in this example if you remove the steps from batch mode, or add those steps to the one piece flow. 😊

[@TrestonUSA]

Actually, the steps are the same in both methods, just done in a different order. In this case, one-piece-flow is a better choice. But we understand that not all work flows are created the same and sometimes batch production may make more sense for some companies.

[@FerrumCorde]

This isn't batching at all. If you were batching, The boxes would have been pre assembled, before the order came in. Any Item that 100% of the time always results in the same end, should have been finished before she started. There is nothing faster about One piece flow, and it's really ablitist to assume everyone's brain responds better to 1 or the other. I am ADHD and on the spectrum. I could easily whoop this employee's butt using proper batching methods, and have this done in under 30 seconds. Another example of the "corporate meeting good idea fairy"

[@gte717v]

Do you have any material I could look into to see this? In practical applications, especially in manufacturing, one-piece flow isn't just faster, but results in less WIP which further saves money and space.

[@FerrumCorde]

Every environment is totally different, The issue is selling it as a policy and favoring it over items that should obviously be prepped in batches due to working with various materials, or mental strain on the party involved. Batching gives you alot more control, and less variation in your end product.. It's counter productive to a khaban environment, even if it might be "cheaper" in the short term. The scale is a huge factor. Your automation is a factor. If Your going to commit to doing it right, develop the tools to handle your batch size. More product doesn't = more time. At best, Single item flow should be like a line cook, who already has all of the pieces prepped, and batched, ready to serve per order.

[@gte717v]

@@FerrumCorde No.

[@cam96934]

It would also depend of what state the item is in, are they working with the Rae material, Intermediate (work in process item) or Finished Good? I agree, it depends on the setup, procurement, and how the workflow is set up