Continuous flow (aka one-piece flow) refers to the situation in which a product or part is processed and moved between process steps one at a time, without waiting or accumulating inventory between workstations. In ideal state a product should flow through entire value stream, from raw materials to the hands of customer. Achieving this state can be too difficult at the beginning. It is good to focus first on the process or segment of value stream in which a product takes a final shape as expected by customer ? this part of a value stream is called pacemaker. It is the most important part of every value stream, because the way a pacemaker operates influences both how good you are in fulfilling customer demand and what demand do you create for upstream processes.

The training will be focused on equipping participants with the ability to see and feel the flow. Manually operated cells and lines will be analyzed as they are widespread in industry, and ? in the world of geographically scattered customers and short product life cycles ? it is important to be able to design and manage simple, inexpensive, flexible and reliable processes operated manually by people. We will present methods and approaches based on best practices, which will be applicable in almost every place you want to create continuous flow.

Dedicated Training

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Expected Training Results

After the training participants will be able to:

  • See the flow and possibilities to improve it
  • Design and plan implementation of continuous flow lines in systematic way
  • Use analysis and optimization methods
  • Production leaders
  • Line managers
  • Process engineers

Training Plan


Introduction to continuous flowlecture + discussion
Creating continuous flow: process analysis, Operator Balance Chart, machines, materials, flow layout, standard worklecture + discussion + examples + exercise
Response to changing customer demandslecture + examples
Implementing, maintaining and improving flowlecture + discussion + examples
Training summarydiscussion

Option: two additional workshop days ? maximum group of 12 people


Choosing the pilot areaworkshops
Creating work teams and setting up the tasks and responsibilitiesworkshops
Process analysis: time studies, process sequence, spaghetti diagram, material use and delivery, working toolsworkshops
Summary and presentation of analysis results. Operator balance chartworkshops


Creating new koncept of line organization: calculating number of operators needed, work balancing, process layout, material presentation, line supply, workplace organizationworkshops
Documenting project of changesworkshops
Calculating cost and benefitsworkshops
Implementation planworkshops
Presentation for management and workshops summarypresentation + discussion