We solve various problems that arise in the complex modern manufacturing environment.
The continuous flow production method is a production system 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 passing time for each process is regulated by a detailed production plan. In other words, by fundamentally improving the production management system centered on the "flow of information," which is not present in traditional improvement activities, this method aims to achieve stable production without changes to the production plan while also reducing manufacturing costs to improve 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 managed in detail, it allows for the identification of waste in operations and issues in the flow of processes. To realize this continuous flow production method, improving 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 system is a new production method developed to solve issues faced by modern manufacturing, such as small-batch production of various items, inventory reduction, and ultra-short delivery times. 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 in one-piece flow production, it enables production based on confirmed orders rather than forecasts, allowing for stable production without confusion. As a result, it can improve productivity and reduce inventory, while also lowering the cost level of the factory and achieving a low-cost structure. This production method is particularly suitable for companies that require small-batch production of various items, those demanding short delivery times, companies experiencing confusion in production lines 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, in continuous production, rather than making partial improvements, the production system itself is changed, 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 benefits of continuous production.
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Company information
Our company was founded in 2001 and provides practical consulting to support improvement activities in the manufacturing industry, including revenue enhancement, productivity improvement, lead time reduction, and inventory reduction through the introduction of DX systems. Based on our unique production management method, the "One-Piece Flow Production System," we create tailored original programs that address each company's specific management challenges, progressing from "on-site improvements" to "system improvements" and then to "production innovation," providing appropriate solutions. If you encounter any issues that need to be resolved, please feel free to contact us. We will definitely provide solutions that satisfy your company. [Astec Consulting HP] https://www.ast-c.co.jp/