Tag Archives: Shopfloor

Visual Management

Yet another hot topic in lean manufacturing is visual management. This can be very helpful in running a shop floor, but when done wrong it can also be quite wasteful and embarrassing. In this post I would like to show you the basic principles of visual management with a few examples. There is more to visual management than merely putting lines on the shop floor.  Continue reading Visual Management

Changeover Sequencing – Part 1

The sequence of your changeover can have quite an impact on the duration of the changeover. In this series of posts I will show some approaches on how to improve your changeover durations by carefully sequencing the products. This was initially intended to be one post, but as so often happens, it turned out to be more complex than initially thought, and hence I have split it into two posts. The next post will appear next week. Continue reading Changeover Sequencing – Part 1

Pacing of Flow Lines 2 – Continuously Moving Line

In my last post I described the pacing of pulse and unstructured flow lines. Another common way to structure the pacing of flow lines is the continuously moving line. In  this type of line, the parts are always moving, and the processes and workers move along with the part until the process is completed. Continue reading Pacing of Flow Lines 2 – Continuously Moving Line

Pacing of Flow Lines 1 – Unstructured and Pulse Line

Flow lines are often the best and most organized approach to establish a value stream. Hence, for flow lines or flow shops you can organize the processes much more easily than for many other types of production systems.

In this series of posts I will look at and compare different ways to pace your production processes. Please note that this is not line balancing about the work content for each process, but rather different options on when to start the work for each process. In the first post I will look at unstructured pacing and pulse lines. In my next post I will go into detail for the continuously moving line. Continue reading Pacing of Flow Lines 1 – Unstructured and Pulse Line

Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines

line-layout-overviewThe layout of a line can make quite a difference in the performance of your line. The U-line is most famous, although in my view while good it may not be the right thing for all situations. There is also the I-line, the S-line, and the U-line. In my last post I described some general thoughts on line design and took a look at the big picture.  In this post I want to look at and compare actual line layouts, in particularly the I, U, S, and L layout. Let me give you an overview of the different options. Continue reading Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines

Line Layout Strategies – Part 1: The Big Picture

Ford assembly line 1913In flow shops, you have a production line of some sort. This may be an assembly line or a manufacturing line; this may be automatic or manual. In lean, you often hear about the famous U-line.

While this is a great solution, it may not fit all problems. Depending on the surrounding conditions, a different line layout may be beneficial. This post is the first in a series on line layout. In this post I would like to discuss what you should consider when designing a new line layout. The next post will look at actual line layout options. Continue reading Line Layout Strategies – Part 1: The Big Picture