More About Flow

OK, let’s talk just a little more about FLOW and then I’ll move on. Back to the airport. You and 9 friends are traveling somewhere – let’s say Florida (get it…flow-rida?!). You have to go through ticketing and security. If it takes each...

Understanding Flow

Let’s analyze the journey taken by a piece of material as it moves through a plant. There are 4 “states of being” for the material: Process The part is being worked on. It’s being machined, polished, spit-shined, whatever. Set-up The time the part is...

Avoid the Mistake of Locally Optimizing

Since the bottlenecks dictate throughput, other processes in the factory should be run to complement the bottleneck’s output. What does that mean, you ask? It means that running a machine just for the sake of running it does not actually add value in most cases....

Improve the Throughput of Bottlenecks

Going back to the boy-scouts walking in a line analogy, the whole troop can only arrive at the campsite when the slowest boy arrives. The slowpoke – the bottleneck – determines the throughput. This insight leads to an interesting conclusion. Once Alex identifies the...

Game of Matches

Here is a super fun game you can play with friends at a campsite to teach them about bottlenecks and flow and statistical fluctuations and dependent events. Your friends will love it. Put 5 containers in a row. Call them container A, container B, and C, D, E. These...

Bottlenecks

The single-file line analogy identifies the concept of bottlenecks. Bottlenecks are the slowest part of your system: the slow kid in line, the slowest machine, the narrow part of the clear plastic container through which liquid flows. Bottlenecks determine your...