Q 555. Compare the concepts of batch processing and one-piece flow in lean. What are the factors that influence the choice between the two? How do they affect the quality, productivity and lead times of the products? Provide at least 2 examples for each methodology in use.

 

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To select process between the two methods, include the size and layout of the production facility, the cost of resource, material and delivery time. The decision should be based on an analysis of the production process & needs of the Org.- lean production system.

 

Batch processing - Set of similar products in a single batch and Batch Qty- very high Volume. This process is used to achieve economies of scale and reduce setup times. But this will lead to high inventory, longer lead times, and Low quality & high WIP material.

 

One-piece flow- Demand is very high with high variability with customization, required equipment and technology available, the skilled worker. One-piece flow focuses on manufacturing a single product at a time.- Volume is low can be define in numbers / Kg also

 

 

Example  of batch Production

1.      Pharmaceutical company- Batch production with high volume required to get same Quality in each product. And change over required high lead time

2.      Steel manufacturing company- batch Production defines by heat Number for Very High Volume – 100T, If Rejected due to quality - Total batch need to be scarp. Lead time is very high

 

One-piece flow focuses on manufacturing a single product at a time.- Volume is low can be define in numbers / Kg also

 

Example of One piece flow

1.      Automobile- Production line – One piece flow – With less cycle time- Product can be deliver with single unit hence High productive. Also Quality if also good. If rejection occurred- only in single unit. Toyota archive one piece flow- where all unit different colour specification within Zero minute changeover.

2.      Appliance- One piece flow –batch size is very small, material required Just in time.

 

One-piece processing focus on producing based on customer need. This helps to maintain good control on cost, as we do not have to mass product and wait. This method also will have better quality as we can focus closely on a piece being processed. Productivity is also better as the piece flow without any waiting time between processes. Lead time also will be better as focus is to cater to a specific need of the customer on demand. Cost benefit analysis is needed to figure out if the cost of building at the last moment for the customer need balances with the building in batch. Manufacturing of car would be good example of one-piece processing based on customer demand. One-piece processing also would lead to low employee morale as there is no variety in the work processing.

In case of batch processing, there is initial investment in setting up the process, but once the processing starts outputs are high and it will be productive process. Quality may be challenges as the processing is in a batch. Cost of processing will be relatively better than one piece processing. Batch processing suits well for the business that have low shelf life of the raw materials like bakery products processing. Waiting time is an issue as the batches has to wait until the next process is ready.

Based on the needs of the companies combination of both the approaches may work well. Study of the business is needed to devise right batch size for the processing.

The decision to choose between batch processing and one-piece flow depends on several factors, including that of:

1. Product Characteristics: The nature of the product that is being manufactured can greatly influence the choice between batch processing and one-piece flow. If the product has a high volume and is repetitive in nature, batch processing may be more efficient. On the contrary, if the product has a low volume and requires customization, one-piece flow may be more effective.
2. Demand: The level of demand for the product is also an vital factor. If the demand is high, batch processing may be more efficient as it can produce a large volume of the product rapidly. However, if the demand is low, one-piece flow may be more effective as it can produce the required quantity without creating excess inventory and avoids waste - Pull rather than Push.
3. Equipment: The type and capacity of the equipment used in the production process can sometime influence the choice between the two. If the equipment is designed for batch processing, it may be more efficient to use this method. However, if the equipment is flexible, meant for customization and can handle small batches, one-piece flow may be more effective.
4. Labour: The availability and skill level of the workforce can also influence the choice between batch processing and one-piece flow. If the workforce is highly skilled and can work efficiently in a one-piece flow environment, this method may be more effective. However, if the workforce is less skilled, batch processing may be a better option as it requires minimal skill and training.
5. Cost: The cost of production is one of the most important factor to consider. Batch processing may be more cost-effective as it can produce a large volume of the product quickly. However, one-piece flow may be more cost-effective in terms of reducing inventory, reducing lead times, and improving quality.

Overall, the decision to choose between batch processing and one-piece flow should be based on a careful analysis of the above factors and should be aligned with the organization's goals and objectives.

The selection between batch processing and one-piece flow can have significant impacts on quality, productivity, and lead time in a manufacturing process.

Quality: Batch processing can result in higher defect rates as it can produce a large volume of defective products before the defect is identified and corrected. One-piece flow, on the other hand, allows for immediate detection and correction of defects, resulting in higher quality products.

Productivity: Batch processing can result in longer setup times and longer processing times, which can reduce productivity. One-piece flow, on the other hand, can reduce setup times and processing times, resulting in higher productivity.

Lead Time: Batch processing can result in longer lead times due to the time required to produce a large volume of products before they can be shipped. One-piece flow, on the other hand, can reduce lead times as products can be produced and shipped in smaller quantities and with shorter processing times.

All in all, one-piece flow can result in higher quality, higher productivity, and shorter lead times due to its ability to reduce defects, setup times, and processing times. However, batch processing may still be a viable option for high-volume, repetitive products, or when equipment is not flexible enough to handle small batches.

 

Eventually, the selection between batch processing and one-piece flow should be based on a careful analysis of the product characteristics, demand, equipment, labour, and cost, and should align with the organization's goals and objectives.

Batch processing examples:

 

 

• Food and beverage industry - producing large batches of canned or bottled products, such as soft drinks or canned vegetables.
• Bakery: Most bakery uses batch processing to produce large volumes of bread. The dough is mixed in large batches, which are then divided into smaller batches for shaping, proofing, and baking.

• Pharmaceutical industry - producing large batches of medications or supplements, such as tablets or capsules.
• Textile industry - producing large batches of fabrics or garments, such as a batch of 5000 t-shirts.

One-piece flow examples:

 

• Automotive industry - producing individual car parts or subassemblies, such as engines or transmissions.
• Aerospace industry - producing individual airplane parts or subassemblies, such as wings or landing gears.
• Electronics industry - producing individual circuit boards or electronic components, such as microchips or resistors.

Congratulations to Mohamed Asif for winning this one with a well-articulated response that includes good examples.