Introduction to Continuous Flow Production Method

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.