Flow in a manufacturing industry

A flowing river will be pure than stagnant water, since pure water will be coming into it from the source and contaminated water is replaced with pure water in it. Just reminded the importance of flow. With this example lets move to flow in a manufacturing industry.

Let’s start …

What is flow

Flow is a movement of a material from a start point to its destination. Without stoppage is the ideal condition in lean manufacturing.

Flow in a manufacturing Industry

In a manufacturing industry flow refers to the movement of materials from start point to its destination. Inside a manufacturing industry, start point will be raw material store and destination will be shipping area.

Outside a manufacturing industry, start point will be the shipping area of supplier and destination will be customer.

Information also flows inside and outside the manufacturing industry. This information flow leads to the flow of material.

How to induce flow in manufacturing industry

For a material or information to flow, initially there should be a driving force.

Demand is the driving force in a manufacturing industry. This demand is transmitted from the customer to the supplier and to the production floor up to shipment area.

Demand is transmitted as information and its done through the implementation of Kanban system.

Importance of flow

Think about, what if a material do not flow…

Following situations will arise,

• Inventory build up
• It will block cash flow (Invested money is blocked without giving return on investment)
• Consumes floor space
• Non moving material will leads to deterioration
• When material is not moved at right time, it may results in the idleness of resources such as manpower and equipment.
• Lead time will increase
• It will results in many of seven wastes

So, if we implement flow the above points can be eliminated from manufacturing industry.

Continuous flow

Continuous flow in a manufacturing industry focus on optimum movement of material. Material movement path usually designed in ‘U’ shape or straight line for reducing the zig zag movement. Which will drastically reduce the movement path and hence saves energy and time.

Lean flow

Lean flow focus on movement of materials in right quantity at right time. Continuous flow comes under lean flow.

Restrictions to the flow in manufacturing industry

Following are the restrictions…

• Changeovers
• Breakdowns
• Material shortages
• Defective parts
• Unorganized work stations
• Lack of proper communication of demand
• Unbalanced cycle time of operations
• Poorly designed layout

How to overcome restrictions

Thank you for reading and supporting us.

If you know any subject that can be related to manufacturing industry or industrial engineering, you can earn some income by becoming article contributor of this website. For knowing more about it, please visit Join us page.

You don’t need to have any experience in article writing, just knowledge on the subject is needed.

Also you can know more about our team of article contributors by visiting the about us page.

LATEST ARTICLES FROM KNOW INDUSTRIAL ENGINEERING

• KIE Factory Stories: Why Did the Customer Pay for a Product That the Factory Never Made?
  A MESSAGE FROM THE FOUNDER PODCAST Ever wondered who’s behind Know Industrial Engineering? Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— The Finance Manager was reviewing the monthly production report when he noticed something unusual. Advertisement The factory had… Read more: KIE Factory Stories: Why Did the Customer Pay for a Product That the Factory Never Made?
• What is a Bill of Materials (BOM) and Why Is It Important in Manufacturing?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is a Bill of Materials? Advertisement A Bill of Materials (BOM) is a structured list of all the raw… Read more: What is a Bill of Materials (BOM) and Why Is It Important in Manufacturing?
• KIE Factory Stories: Why Did the New Operator Outperform Everyone Without Working Faster?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— The production supervisor was checking the output board when he noticed something unusual. Advertisement The newest operator had completed almost… Read more: KIE Factory Stories: Why Did the New Operator Outperform Everyone Without Working Faster?
• What is a Reorder Point and How Does It Prevent Material Shortages?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is a Reorder Point? Advertisement The Reorder Point (ROP) is the inventory level at which a company should trigger… Read more: What is a Reorder Point and How Does It Prevent Material Shortages?
• KIE Factory Stories: Why Did the Supplier Deliver Perfect Parts That the Factory Couldn’t Use?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “The parts passed every inspection. Why is Production rejecting them?” Advertisement The Purchase Manager was frustrated. The supplier had delivered… Read more: KIE Factory Stories: Why Did the Supplier Deliver Perfect Parts That the Factory Couldn’t Use?
• What is Safety Stock and Why Is It Important in Manufacturing?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is Safety Stock? Advertisement Safety stock is the extra inventory maintained to protect production against unexpected demand increases, supplier… Read more: What is Safety Stock and Why Is It Important in Manufacturing?
• KIE Factory Stories: Why Did the Supervisor Stop Praising His Best Team?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “Another record! You have beaten last month’s production target.” Advertisement The Plant Head was delighted. The assembly team had increased… Read more: KIE Factory Stories: Why Did the Supervisor Stop Praising His Best Team?
• What is Material Handling and How Does It Improve Factory Productivity?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is Material Handling? Advertisement Material handling is the movement, storage, protection, and control of materials throughout manufacturing, from receiving… Read more: What is Material Handling and How Does It Improve Factory Productivity?
• KIE Factory Stories: Why Did the Factory’s Electricity Bill Rise Even When Production Fell?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “We produced fewer parts this month. Why is our electricity bill higher?” Advertisement The Plant Head looked at the energy… Read more: KIE Factory Stories: Why Did the Factory’s Electricity Bill Rise Even When Production Fell?
• What is a FIFO Lane and Why Is It Important in Production?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is a FIFO Lane? Advertisement FIFO stands for First In, First Out A FIFO lane is a controlled buffer… Read more: What is a FIFO Lane and Why Is It Important in Production?
• KIE Factory Stories: Why Did the Plant Head Cancel the Factory’s Biggest Production Run?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “We have enough orders to keep this machine running for three days. Why are we stopping?” Advertisement The Production Manager… Read more: KIE Factory Stories: Why Did the Plant Head Cancel the Factory’s Biggest Production Run?
• Overall Labour Productivity in Manufacturing:Measuring Output Per Worker
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What Is Labour Productivity? Advertisement Labour productivity measures how much output is produced using a given amount of labour. In… Read more: Overall Labour Productivity in Manufacturing:Measuring Output Per Worker
• KIE Factory Stories: Why Did the Finance Manager Visit the Scrap Yard?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— The Production Manager was surprised to see him there. Advertisement “What are you doing here? Looking for something?” The Finance… Read more: KIE Factory Stories: Why Did the Finance Manager Visit the Scrap Yard?
• What is Jidoka in Lean Manufacturing?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— Jidoka is a Lean Manufacturing principle that enables a process or machine to detect an abnormality and stop or alert… Read more: What is Jidoka in Lean Manufacturing?
• KIE Factory Stories: Why Did the Operator Refuse to Follow the Standard Procedure?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “The procedure says to do it this way. But I know a faster way.” Advertisement The supervisor was ready to… Read more: KIE Factory Stories: Why Did the Operator Refuse to Follow the Standard Procedure?
• What is A3 Problem Solving?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— A3 Problem Solving is a structured approach to understanding problems, identifying root causes, developing countermeasures, and monitoring results. Advertisement It… Read more: What is A3 Problem Solving?
• KIE Factory Stories: Why Did the Plant Head Reject a ₹20 Lakh Cost-Saving Proposal?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “We can save ₹20 lakh every year.” Advertisement The Finance Manager was impressed. The engineering team had proposed removing a… Read more: KIE Factory Stories: Why Did the Plant Head Reject a ₹20 Lakh Cost-Saving Proposal?
• What is 8D Problem Solving and How Does It Help Manufacturing Quality?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is 8D Problem Solving? Advertisement 8D (Eight Disciplines) is a structured problem-solving method used to investigate recurring quality issues,… Read more: What is 8D Problem Solving and How Does It Help Manufacturing Quality?
• What is Gauge R&R and Why Is It Important in Quality Control?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is Gauge R&R? Advertisement Gauge Repeatability and Reproducibility (Gauge R&R) is a measurement system analysis method used to determine… Read more: What is Gauge R&R and Why Is It Important in Quality Control?
• KIE Factory Stories: Why Did the AI System Approve a Defective Part?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “The new vision system has approved all 500 parts.” Advertisement The Quality Manager looked relieved. The factory had installed an… Read more: KIE Factory Stories: Why Did the AI System Approve a Defective Part?
• How to Grow Faster in Your Manufacturing Career: The Knowledge, Strategies and Decisions That Make the Difference
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— Why do some manufacturing professionals become managers and plant heads while others remain in the same positions for years? Discover… Read more: How to Grow Faster in Your Manufacturing Career: The Knowledge, Strategies and Decisions That Make the Difference
• What is Statistical Process Control (SPC) and How Does It Improve Quality?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is Statistical Process Control? Advertisement Statistical Process Control (SPC) uses statistical methods to monitor a manufacturing process and understand… Read more: What is Statistical Process Control (SPC) and How Does It Improve Quality?
• KIE Factory Stories: Why Did the HR Manager Refuse to Hire More Workers?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “We need six more operators. Otherwise, we will miss the monthly target.” Advertisement The Production Manager was frustrated. Orders were… Read more: KIE Factory Stories: Why Did the HR Manager Refuse to Hire More Workers?
• What is a Spaghetti Diagram and How Does It Improve Factory Layout?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is a Spaghetti Diagram? Advertisement A Spaghetti Diagram is a visual tool used in Industrial Engineering to map the… Read more: What is a Spaghetti Diagram and How Does It Improve Factory Layout?
• KIE Factory Stories: Why Did the Plant Head Ask for a Smaller Warehouse?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “We need more storage space.” Advertisement The Warehouse Manager was convinced. Finished goods were filling every available corner. Pallets were… Read more: KIE Factory Stories: Why Did the Plant Head Ask for a Smaller Warehouse?
• What is Performance Rating in Time Study?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is Performance Rating? Advertisement Performance Rating is the assessment of an operator’s working pace compared with a defined normal… Read more: What is Performance Rating in Time Study?
• KIE Factory Stories: Why Did the Engineer Remove a Safety Sign?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “Who removed the warning sign?” Advertisement The supervisor was not happy. The sign had been placed beside a machine after… Read more: KIE Factory Stories: Why Did the Engineer Remove a Safety Sign?
• What is Standard Time in Industrial Engineering and Why Is It Important?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is Standard Time? Advertisement Standard Time is the time allowed to complete a specific task under defined working conditions,… Read more: What is Standard Time in Industrial Engineering and Why Is It Important?
• KIE Factory Stories: Why Did the Purchase Manager Reject the Cheaper Supplier?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— “We can save ₹8 per piece if we switch suppliers.” Advertisement The Purchase Manager expected everyone to agree. Instead, the… Read more: KIE Factory Stories: Why Did the Purchase Manager Reject the Cheaper Supplier?
• What are Value-Added and Non-Value-Added Activities in Manufacturing?
  A MESSAGE FROM THE FOUNDER PODCASTEver wondered who’s behind Know Industrial Engineering?Hear the story of how it started in 2019 and the vision behind Factovare. Listen to podcastListen without leaving this page ▶0:00 / —:— What is a Value-Added Activity? Advertisement A value-added activity is an activity that changes the product in a way the… Read more: What are Value-Added and Non-Value-Added Activities in Manufacturing?