We solve various problems that arise in the complex modern manufacturing environment.
The continuous flow production method is a production approach that allows for the seamless flow of goods from the initial process to the final process without stagnation, based on a highly reliable production plan. The passage time for each process is regulated by a detailed production plan. In other words, by fundamentally improving the production management system centered around the "flow of information," which is absent in traditional improvement activities, this method aims to achieve stable production without changes to the production plan while also reducing manufacturing costs to enhance profitability. Additionally, by creating and managing a detailed production plan at the time level, it becomes possible to determine the shipping date upon order receipt, and because the progress of each process can be closely monitored, it allows for the identification of waste in operations and issues in the flow of processes. To realize this continuous flow production method, enhancing production stability and strengthening the functions of the production management department are key points.
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basic information
The one-piece flow production method is a new production approach developed to address issues faced by modern manufacturing, such as low-volume, high-variety production, inventory reduction, and ultra-short lead time production. It is a production innovation technique that creates a low-cost structure through improvements in the production system (innovating the flow of goods and information). By achieving overwhelming lead time reduction, one-piece flow production enables production based on confirmed orders rather than forecasts, allowing for stable production without confusion. As a result, it can lead to increased productivity and inventory reduction, while also lowering the cost level of the factory and achieving a low-cost structure. This production method is particularly suitable for companies engaged in high-variety, low-volume production, those requiring short lead times, companies experiencing production line disruptions due to sudden reductions, and businesses with short product life cycles.
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Applications/Examples of results
The improvement activities that have been carried out traditionally have mostly been focused on on-site improvements. While there are effects at the workplace or line level, they often do not lead to results for the entire factory or to specific reductions in manufacturing costs. On the other hand, integrated production changes the production system itself rather than just making partial improvements, making it possible to achieve certain results. In particular, the reduction of manufacturing costs through the shortening of production lead times and the lowering of cost levels for the factory can be considered the greatest advantages of integrated production.
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Company information
Our company was founded in 2001 and provides practical consulting to support improvement activities in manufacturing, such as revenue enhancement, productivity improvement, lead time reduction, and inventory reduction, including the introduction of DX systems. Based on our unique production management method, the "One-Piece Flow Production System," we create customized original programs tailored to each company's management challenges, addressing everything from "on-site improvements" to "system improvements" and "production innovation," and provide appropriate solutions. If you encounter any issues that need to be addressed, please feel free to contact us. We will definitely provide solutions that satisfy your company. [Astech Consulting HP] https://www.ast-c.co.jp/