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One-Piece Flow vs. Batching: A Guide to Understanding How Continuous Flow Maximizes Productivity and Customer Value
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About One-Piece Flow Vs. Batching: A Guide To
Product Description Although batching often appears more efficient than one-piece flow for individual tasks, the practice creates waste for other parts of the organization that more than offset its perceived benefits. A silent productivity killer, batching is an extremely difficult mindset to overcome and, as a result, numerous Lean initiatives have been destroyed by it.This book argues the case for one-piece flow over batching. It identifies the eight root causes of batching, the wastes created from batching, how batching drives the eight wastes, and the advantages of one-piece flow.One-Piece Flow vs. Batching: A Guide to Understanding How Continuous Flow Maximizes Productivity and Customer Value provides concrete arguments as to why batching, while sometimes necessary, is never the most efficient solution for most processes. It explains why flow, especially one-piece flow or continuous flow, should always be your ultimate objective when driving for increased productivity in any process.Using case studies to illustrate how to channel current mindsets toward one-piece flow as the preferred operation, the book is designed to support anyone involved in continuous improvement activities. It provides the tools and understanding you will need to overcome resistance to implementing flow and, in particular, one-piece flow processes―whether it be on the factory floor or in a banking office. Review "I highly recommend One-Piece Flow vs Batching by Charlie Protzman, Joe McNamara, and Dan Protzman. ... The authors have put together a series of real life examples of one-piece flow vs batching that really highlight the waste that drives batching. ―Kenneth L. Skiles, Director, Continuous Improvement, Lincoln Electric"I do recommend that you carefully study this book and recognize that batching must disappear to achieve one-piece flow if you want to compete in the world arena."Norman Bodek, Owner, PCS Press"This is the first book I have read that comprehensively confronts the ills of batching in a single volume and provides an alternative. It does so in language that is clear and accessible to all levels in an organization―from CEO to middle managers to workers on the shop floor! A great contribution to the ‘improving productivity’ agenda. Read it!"―Augustus J. Lusack MSc, MBA, Lean Six Sigma Black Belt; Founder: ‘Why Not?’ Solutions Limited; Head of Pathology, Northampton General Hospital, UK "This book is relevant to both newer students of Lean as well as seasoned Lean practitioners looking to gain an insightful understanding of a cause of much waste in our organizations, BATCHING. By presenting numerous examples from many different industries, readers will finish the book appropriately armed to first identify and then eliminate batching."―Kenneth W. Place, Lean Six Sigma Master Black Belt, University of Illinois BIS"I am a batch-person. Whenever there is a chance to batch I have a certain tendency to do so. Charles Protzman’s book made me reconsider this position. I think this is the best one can say about any book. As a ‘good’ scientist I do not agree in all points; but I consider the arguments brought forward for one-piece flow convincing. It is not a dull repetition of you ‘should not batch’ but reasonable arguments against batching are developed. While this sounds not very exciting, practical examples and great writing style make it a very enjoyable read. In short - the authors successfully continue Ohno’s quest towards one-piece flow."―Matthias Thürer, Professor, Jinan University, China"I have spent 38 years in the steel industry in quality assurance, process control, and operations management and have been successful by finding ways to optimize performance by taking advantage of new technology, understanding and controlling process variation, and looking for opportunities to get more for less. Like the plant manager that Charlie dedicated this book to though, I have to admit that I still believe that in some industrie
