One piece flow production is a production system that the required products for customers are flowed “one by one”.
Lot production to produce a certain volume of products may seem more efficient, but when you consider the overall situation in terms of lead time, quality, and inventory, one piece flow production leads to cost reduction, even if it takes a little more work.

Solve these issues
with one piece flow production ISSUE

Lead time reduction
Quality defect
Profit does not grow
Sales do not grow
No idea what to improve
Large inventory

3 points
for one piece flow production FEATURES

  • 1

    Thorough elimination of waste
      Productivity improves through thoroughly eliminating waste clarified by one piece flow production.
  • 2

    Multi-type small-quantity production in a short term
      One piece flow production is capable of producing multi-type small-quantity production in a short term.
  • 3

    Quality improvement
      One piece flow production is capable of reaching the level of 100% quality assurance.
Thorough elimination of waste

Productivity will not increase if only one piece flow production is carried out, but productivity will be improved by thoroughly eliminating waste that has become apparent by carrying out the one piece flow production.
This idea of making such waste visible (making it easy to find waste) is the “Visualization” of the Toyota Production System.
In order to realize one piece flow production, the points are: 1) arranging equipment in process order, 2) stand-up work, 3) U-shaped line, and 4) having multiple processes.

Multi-type small-quantity production in a short term

Line of one piece flow production produces multi-type small-quantity products in a short term. As a shift from a mass production to a multi-type small-quantity production, “one piece flow” is the basic principle.
In multi-type small-quantity production, the point is to produce similar products on the same line by analyzing a wide range of production information using group technology.

Quality improvement

“Own Process Completion” = “Quality must be made in the production process” is to guarantee the quality by taking responsibility for your own work based on the idea of “the following process is your customer”.
Operators produce products according to the conditions of good products and confirm one by one that they are good quality products before sending them to the next process, so they do not send defective products to the next process.
Even if operators make a defective product, they inspect what they have made by themselves now, so they can immediately understand the cause of the defect and prevent reoccurrence.

Consultants from major companies
with experience in over 40 countries will respond.
Please feel free to contact us.

If you are in a hurry, please call us.

03-5783-3571
Open 08:30 - 17:30
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays
One piece flow production specialist
ITO, Akihiro

Process improvement consultant

Akihiro Ito is active on the front line as a shop floor improvement consultant. He has improved a wide variety of large and medium-sized shop floors of over 300 companies in more than 12 countries in Japan and overseas, and has solved the problems of each shop floor every time. Based on his experience working on the production control system, he implements improvement activities in all processes of a factory such as sales, materials, production control, manufacturing, and outsourcing. In addition, he implements the improvement activities together with the people at the shop floor, make the culture of shop floor improvement rooted in the company, and realize quality improvement, productivity improvement and lead time reduction.

Case example of Genba Kaizen Consulting RESULTS

Acquired orders from two new customers
by improving quality.

We reduced most work-in-progress inventories and defective inventories, which were found throughout the factory, and reduced manpower, and now we almost no longer receive customer complaints that we had every month before. (Automobile industry / Plant manager)

Turn the factory into a showroom
in order to improve profitability

We improved 250 cases out of 300 cases pointed out by the 5S patrol conducted for one year. The factory was realized to be the showroom and also achieved cost reduction of 30 million yen per year. (Metal processing / Director)

Productivity Up to 169.6%
by 6 months of improvement activities

the Japanese president decided to outsource a shop floor improvement consulting to have their shop floor checked, and asked us, Hirayama Consulting.(Auto parts manufacturer/Managing director)

3 reasons why we are chosen REASON

REASON 1

Improvement experience of
more than 1,000 companies in 40 countries

There must be the shop floor issues that cannot be solved by your own company alone. Improvements and reforms for manufacturing industry to survive, regardless of country or industry, need development of your human resources through practical experiences of improvement, and strengthening of your production system base.

REASON 2

Consulting that shop floor workers
acknowledge our superiority and be pleased

In conventional consulting styles, there was a distance between consultant and the shop floor because it was promoted mainly consultant and management executives. Our consultant can provide a guidance without a distance between consultant and the shop floor through the guidance based on the "seeds of improvement" in a concrete way, instead of "finding fault" like a critic.

REASON 3

Continuous improvement will continue
even after the end of guidance

While strengthening "human resource development", we focus on the "overall flow" from design to purchasing, manufacturing, logistics, and production control, and provide guidance that matches the actual situation of your company. Continuous improvement will continue even after the end of guidance through the guidance that is acceptable to the shop floor workers.

Consultants from major companies
with experience in over 40 countries will respond.
Please feel free to contact us.

If you are in a hurry, please call us.

03-5783-3571
Open 08:30 – 17:30
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays