Lean Manufacturing One Piece Flow vs. Mass Production Paper Airplane Simulation (Lean Tip 005)

See how to transform slow and wasteful mass production into lean one piece flow in this simple and fun paper airplane simulation.

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Thank you for watching - I really appreciate it :)

Cheers,
Daniel | Lean Smarts

[erikkaareandersen]

This video - and many similar - aims to illustrate the 'large' benefits of reducing batch sizes. It primarily illustrates is the effect of idling resources; resources in the batch process are idle half of the time. In a continuous flow, the throughputs are identical and independent of the batch sizes, i.e. the productivity is identical. The benefits of reducing batch size come from the reduced WIP and/or cycle time. And then we are back to the discussion of the trade-off between transaction costs and holding costs - or efficiency versus speed

[JohnSmith-vszf]

One peeve I have with this type of example (here and other places I've seen similar ones) is that most of the improvement comes from making station 2 work at the time as station 1 as opposed to sitting around waiting. In real life, you're probably going to be continuously doing batches of 5, in which case (after the very first batch) both stations are already going to be working simultaneously. In that case, there can be benefit to one piece flow, but not necessarily... you have to take into account set up time and the like.

[MrCrazyPiscean]

I'm glad to find your demonstration clip on production systems. This is the best practical explanation with great editing ever! What an effort! Thank you for your time! I really noticed each n every part of the process. 🙏😩

[marfipeval]

Great Explication... Thanks for this video

01:04 First Process
01:46 Start First flow
05:10 Start second flow

[yazannofal]

Thanks Daniel, that's the best explaination I've seen online so far, and I think there won't be a more fantastic video than yours

[ralphschraven]

In this example, you can eliminate the idle time of the workers entirely by letting both of them do the entire process separately from one another. Also, it looks like you could do the first three folds with the entire batch of 5 stacked on top of one another. One more thing worth considering is that you can do folds 2 and 3 simultaneously with your left and right hand. Perhaps a "press" of some sort would also help speed up the process of carving out the lines in the paper, much like Japanese printmakers do, albeit in a different way, with special wooden tools. Interesting example!

[harveytseng]

Simple but straight to the points of saving

[sjsphotog]

FANTASTIC demo of 1 piece flow. Great job and very funny. great editing. I love your evil twin brother :P keep it up

[joshc]

In a realistic production situation there would have been approx. twice as much produced in the batch scenario, as in the video both workers were idle for around half the time. Normally they would have been finishing the previous batch or starting the next.The time saving is in the elimination of picking up and putting down the paper, so it's a lot less than the video shows on face value but still worthwhile.

[danymendez]

it's an simple and amazing example to understand one piece flow!!!

[paulerapedreira]

Neat video editing, the handover moment looks pretty smooth. Also, neat explanation of one-piece flow, thanks for sharing!

[oluwakemidare-idowu]

This is an awesome and effortless explanation. Thank you so much, Daniel. It is the best explanation I have seen online so far.

[hamiltonh.]

Hola
Tu explicación fue mucho más clara que la que me enseñaron en un taller de 4 HORAS.
Muchas gracias.

[michaelnyamu]

Wonderful i will effect this in my garment production

[LetsChat]

I'm convinced this man has a twin.

[kutlukul]

thanks for sharing. awsome explanation.

[axeu]

Very interesting video !
But if there is only 1 batch to produce, this video is ok but in real production, when department 1 is producing batch N, department 2 is not waiting but finishing to produce batch N-1.
Then when dept 2 is finishing batch N, dept 1 is starting ton produce batch N+1.

That would be interesting to explain that for batch production : they finish 2 batches within 4min59, batch N-1 then batch N (so 29, 9 sec/pcs),
then with one piece flow : they finish 1 + 5 pieces within 1min47 (so 17, 8sec/pcs).
So -41% process time / pcs

Lean is the way \o/

I work as a welder, and this technique works on some of the products, but not all of them.

[selvaprasanth]

Nice explanation with excellent and simple ideas

[franklinm]

Well said!! 👍 great simple explanation.