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.

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Upcoming Six Sigma trainings

Creating continuous flow cells and lines
Fall 2021   800 pln
To take part in an open training, you should complete the application form and send it to us: For those, who will send their application 30 days prior to the workshop,we offer a discount of 10%!

Training Price includes

  • Ability to consult with a trainer during the training and after the workshops
  • The training conducted by experienced trainer
  • Training completion certificate
  • A set of training materials
  • Additional training materials based on the individual needs of the trainee
  • Username and password for the Client Zone allowing use of many additional materials
  • Coffee breaks and lunch

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 flow lecture + discussion
Creating continuous flow: process analysis, Operator Balance Chart, machines, materials, flow layout, standard work lecture + discussion + examples + exercise
Response to changing customer demands lecture + examples
Implementing, maintaining and improving flow lecture + discussion + examples
Training summary discussion

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


Choosing the pilot area workshops
Creating work teams and setting up the tasks and responsibilities workshops
Process analysis: time studies, process sequence, spaghetti diagram, material use and delivery, working tools workshops
Summary and presentation of analysis results. Operator balance chart workshops


Creating new koncept of line organization: calculating number of operators needed, work balancing, process layout, material presentation, line supply, workplace organization workshops
Documenting project of changes workshops
Calculating cost and benefits workshops
Implementation plan workshops
Presentation for management and workshops summary presentation + discussion