Flow Brings Problems to the Surface
"Sustaining continuous flow also serves to surface any problem that would inhibit that flow. In essence, the creation of flow forces the correction of problems, resulting in reduced waste. We…
Fake Flow?
"Many companies change the physical layout of equipment and think that one-piece flow will automatically follow. But they often are creating fake flow. An example of fake flow would be…
Too Much Inventory Reduction Can Hurt
"Sustaining continuous flow also serves to surface any problem that would inhibit that flow. In essence, the creation of flow forces the correction of problems, resulting in reduced waste. We…
Discover the Weak Points and Improve
"So physically shifting from batch and queue operations…to one-piece flow without inventory almost guarantees you will encounter many more problems. So why do it? Precisely to allow the processes to…
Flow and the Pursuit of Perfection
"Connected processes force all team members to strive for perfection. [Toyota Manager] Ohno taught that lowering the 'water level' of inventory exposes problems (like rocks in the water), and you…
The Benefit of One-Piece Flow
"One of the greatest benefits of one-piece flow is that problems surface and challenge people to think and improve." The Toyota Way 2nd Edition by Jeffrey K. Liker (McGraw Hill,…
Flow: Challenging People to Think and Improve
"Toyota's vision of any process is true one-piece flow that is waste-free. Creating flow means linking together processes that otherwise are disjointed. When operations are linked together, there are opportunities…
Batching in the Restaurant Business
"We know from long experience that making elements of the finished product, such as steamed milk, in batches might seem efficient, but it creates a lot of waste. Especially when…