Choosing Batch Sizes and One Piece Flow | Rowtons Training by Laurence Gartside

Choosing Batch Sizes and One Piece Flow
𝐅𝐑𝐄𝐄 𝐄-𝐁𝐎𝐎𝐊- 𝟏𝟎 𝐬𝐭𝐞𝐩𝐬 𝐭𝐨 𝐏𝐫𝐨𝐩𝐞𝐥 𝐲𝐨𝐮𝐫 𝐂𝐚𝐫𝐞𝐞𝐫 𝐢𝐧 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐬 𝐌𝐚𝐧𝐚𝐠𝐞𝐦𝐞𝐧𝐭
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Batch Sizes are a very important operations management decision. How many units of work a process does before passing it along to the next has a huge and direct influence on everything from customer lead time, discovering quality mistakes, work-in-progress quantity, inventory costs and customization options.
What benefits will your operations get from reducing batch sizes and could the famous lean manufacturing ideal of "one piece flow" be for you?
𝐅𝐑𝐄𝐄 𝐌𝐢𝐧𝐢 𝐕𝐢𝐝𝐞𝐨 𝐂𝐨𝐮𝐫𝐬𝐞 - 𝐓𝐡𝐞 𝐅𝐨𝐫𝐠𝐨𝐭𝐭𝐞𝐧 𝐅𝐮𝐧𝐝𝐚𝐦𝐞𝐧𝐭𝐚𝐥𝐬 𝐨𝐟 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐬 𝐌𝐚𝐧𝐚𝐠𝐞𝐦𝐞𝐧𝐭
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📊 𝐎𝐏𝐄𝐑𝐀𝐓𝐈𝐎𝐍𝐒 𝐌𝐀𝐍𝐀𝐆𝐄𝐌𝐄𝐍𝐓 𝐀-𝐙
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🚚 𝐒𝐔𝐏𝐏𝐋𝐘 𝐂𝐇𝐀𝐈𝐍 𝐌𝐀𝐍𝐀𝐆𝐄𝐌𝐄𝐍𝐓 𝐀-𝐙
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⚠️ 𝐒𝐀𝐅𝐄𝐓𝐘 𝐒𝐓𝐎𝐂𝐊 𝐂𝐀𝐋𝐂𝐔𝐋𝐀𝐓𝐈𝐎𝐍 : Inventory Control
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📊𝐒𝐔𝐏𝐏𝐋𝐘 𝐂𝐇𝐀𝐈𝐍 𝐊𝐏𝐈s
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𝐅𝐑𝐄𝐄 𝐄-𝐁𝐎𝐎𝐊- 𝟏𝟎 𝐬𝐭𝐞𝐩𝐬 𝐭𝐨 𝐏𝐫𝐨𝐩𝐞𝐥 𝐲𝐨𝐮𝐫 𝐂𝐚𝐫𝐞𝐞𝐫 𝐢𝐧 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐬 𝐌𝐚𝐧𝐚𝐠𝐞𝐦𝐞𝐧𝐭
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[@ignacionahuelfalugue569]

i was just having trouble to understand the process batch and transfer batch concepts mentioned in the theory of constraints book. It is so clear now. Great video.

[@LaurenceGartside]

Glad it helped!

[@captt9312]

@laurence thanks for proving insight on batch sizes. I have a question how do we make suggestions about batch sizes and production numbers right?
Shall we do that in Excel or is there any other preferred tool ?

[@LaurenceGartside]

There's no "one size fits all" solution. Your business and its particular maturity, market and strategy will have unique factors that influence your decision. First is to understand the options and implications of batch size decisions. There are many calculation methods. I cover several of them in my "Lean Manufacturing A-Z" course on Rowtons Training.com. Excel can be appropriate for small and dynamic situations whilst specialist software becomes worth the effort as you have more SKUs and more established business processes.

[@rzen19]

Doesn't the transfer of every one piece adds time to the whole process? If the transfer of a batch is 1 min theoretically the transfer of one piece is still 1 min

[@LaurenceGartside]

Transferring batching between process stations can sometimes be a major factor (labour & transportation costs, sometimes, in other industries and situations, it may not be much at all. But (assuming the extra admin burden does not cause extra waiting for transportation), the smaller transfer batches on its own will not increase throughput times because of the "one piece transfers". Each piece will have those same transfer journeys irrespective of the transfer batch size and, as we discuss in the video, the effect on reduced throughput times is a great improvement of working with reduced transfer batch sizes.