What if you could reduce the total production time with a single step?

What if we said that through an amendment process you could decrease production times, increase quality and efficiency, and reduce spending on stock maintenance? Does it sound complicated? The solution may reside in passing from batch production to flow production.


To explain this concept we will use a very simple example. Imagine a car company with three stages for the construction of a vehicle: the body, tyres and painting. Initially, the company decided that the optimal way of producing was to group the cars into ten and send them from one stage to the other in a large lot. If each phase takes a minute per car, then the following results would be expected: the production time of the first car - 21 minutes; the production time of the first lot of ten - 30 minutes.


Now imagine that the cars are produced in a process where each car passes immediately to the next phase in a continuous flow process. Thus, the time to produce the first car would be 3 minutes and the time to produce the first batch of 10 would be 12 minutes. That is, we obtain a reduction of 18 minutes' production time.


To this productivity gain, we would have to add the savings associated with having less stock. This is because, with flow production, the products are made in a one by one process, so they can be produced to meet the market needs.


Another advantage in terms of product quality, considering the flow system, a defect will most likely be detected at an early stage. The fact that production is made according to market configuration also makes it is easier to ensure production is updated. With every new technology cast, the system can be upgraded - something that would have been impossible with batch production.


And this can be adapted to any process and not just in manufacturing. It can be applied in bakeries, for example - making several batches throughout the day and increasing the number of satisfied clients and reducing wasted rolls instead of baking everything the morning. It can also be used for organising tasks in an office. The possibilities are limitless, just as the earnings for companies that adopt these processes.


This is called Flow Efficiency Improvement Strategy and it is a new paradigm of Customer Service Improvement and Process Productivity.

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