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Workflow Defined
Workflow Defined
A Workflow is a defined sequence of tasks that produce a final outcome.
It can be seen as a roadmap for getting a particular job done, typically organized in a systematic, often chronological order.
Workflows are employed in various contexts, from business processes, software development, and manufacturing operations, to manage and guide the activities needed to achieve a specific goal.
Batch vs. One-Piece Flow
Batch vs. One-Piece Flow
At a very high level, all workflows - regardless of the type of work being done - can be categorized performed one of two ways:
Batch/Batching, where workflow steps are completed for multiple quantity (>1, AKA a "batch") of product/service at once
One-Piece-Flow, where workflow steps are completed for single quantity (1) of product/service at once
For several reasons, one-piece flow is the superior method of executing workflows:
Right-Sizing: It reduces the overall equipment size and capacity requirements to the bare minimum, allowing for optimal right-sizing of equipment and production processes. This means that the resources are matched more closely to the actual demand, leading to cost savings.
Waste Reduction: It reduces Lean wastes of overproduction, inventory, waiting, and more
Fast First Part Completion: The first fully-completed product is produced in the minimum time possible, enabling quicker response to customer orders and market demands. This not only enhances customer satisfaction but can also provide a competitive advantage in terms of lead time.
Looking at the Bigger Picture
Looking at the Bigger Picture
Workflows can range and scale from being extremely tactical all the way to being very large & strategic (ex: the workflow of multiple factories across the globe)
Equipment/Process-Based Workflows
Tactical Workflows
(ex: the workflow of a single operation of a single piece of equipment)
Strategic Workflows
(ex: the workflow of multiple factories across the globe)
It is important to consider how workflow changes at one level translate and impact workflows on other levels
Scenarios can exist where improving the workflow at one level can negatively impact the workflow(s) elsewhere
1.2✔ CHECKPOINT
1.2✔ CHECKPOINT
Batching vs. One-Piece Flow
Batching vs. One-Piece Flow
For each of the scenarios listed below, determine the results when the same process/workflow is performed in Batch vs. One-Piece Flow, then analyze your findings and state which is workflow method is superior. Refence the visuals above for each scenario, assuming each station takes 1 minute per part:
SCENARIO A: Defects are introduced to parts at Station 1 due to a worn-out tool. Let's say Station 3 is inspection (where defects are caught/identified) - how many parts are made defective by the time the defect is caught?
SCENARIO B: When starting a new order (no parts in flow except those about to enter Station 1), how many minutes of downtime will each station Operator have before they begin working?
SCENARIO C: At the start of the order (no parts in flow except those about to enter Station 1), how many minutes until the first part is fully completed (has gone through all 3 stations)?
SCENARIO C: An order is about to be completed and the machine/systems needs to be changed over to produce a new order of different parts. The system cannot be changed over until all stations are inactive (not working). The last part(s) are being completed at Station 1. How many minutes of downtime will each station Operator have before the system is ready to changeover?
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