Continuous Flow Online Training Module is designed to help you achieve Continuous Product Flow by performing a lean manufacturing value flow analysis of the activities that create and support your product or service.
Briefly, achieving Continuous Product Flow means that all the tasks and activities are performed in such a way that the product proceeds from design to launch, order to delivery, and raw materials into the hands of the customer with no stoppages, scrap, or back flows.
By performing a thorough analysis of the flow of value (and value is considered the product or service your company provides), the constraints are identified, and eliminated or minimized.
If you are planning to also provide on-site (in-classroom) training for your team, we strongly recommend that, beside taking this module online, you check out our Continuous Flow Presentation (PDF format), and the One-Piece Flow Game (PDF format), which we provide separately, for a one-time cost. When used together during the training session, your team can experience the true power of what they’ve learned.
Although you can start right away on this module, we strongly recommend you first do the following:
- Move from a functional organization to a value stream organization. Only then, you can see the whole pictures of how each department is aligned, and how they are able to contribute.
- And then, start the training and the application of the continuous improvement routines, and the problem-solving methodology. This way, it will be much easier to develop the strategic plan, of closing the gap towards the vision, step by step, year over year.
- Develop your Lean Policy Deployment (Strategic Plan). Value stream mapping is just a way to visualize and prioritize the activities that will be aligned to the vision of producing enhanced value to the customer in the shortest amount of time with minimum overall cost for the business. If the actions are not incorporated in the overall strategic plan, they will not get supported financially and otherwise, or else, what is the purpose of a policy deployment?!
- Draw the Current State Map using the Value Stream Mapping Methodology. Suddenly, now you have a good picture of the current state of the value stream you need to work on, and how it is linked to various value stream (product families). You also have access to financial and people resources, and everything is aligned to the true North. Without these ingredients, your effort will be local at best, and not sustainable, because it’s not enough to stop here, you will need to write instructions, set the standardized work, and train everybody, and this requires a lot of planning and collaboration.
- Clearly Define Flow Principles
- Introduce the Process to Achieve a Flow Line
- Explain the Use of Flow Principles to Improve Your Process
- Explain How to Balance the Line and Achieve One-piece Flow using the principles of Theory of Constraints
- Definition of Flow
- What is Flow?
- History of Flow
- Example of Flow
- Benefits of Creating Flow
- Case Study from VSM Module
- Barriers to Implementing Flow
- Kanban vs. Flow Case Study
- Flow Principles
- Guiding Principles to Flow
- Roadmap to Achieve Continuous Flow
- Identify the Product Family
- Draw the Current State Map
- Identify flow opportunities
- The Flow Index
- The Spaghetti Diagram
- Create the future state map
- Develop and Refine the Implementation Plan
- Develop the New Layout (The tennis court exercise)
- Equipment Considerations
- Material Considerations
- Execute the Future State Plan
- Move processes/equipment closer together
- Stabilize processes (downtime, scrap, cycle time)
- Balance the line
- Reduce batch size to the ideal of one-piece
- Work through the Case Study from the VSM Module
- Reflections on Continuous Flow
- Key Lessons Learned
- Where do we go from here? The Lean Implementation Roadmap.
- The Continuous Flow Training (online only)