Top Ten Benefits of Fork Truck Free with One Piece Flow and Small Lot: Delivery Improves Quality

November 3, 2017 0 Comments Fork Truck Free Info 3818 Views
  1. Improves safety by reducing motion, handling, and forklift movement. READ HERE.
  2. Improves quality by first defecting defects instead of creating a bad batch. READ HERE.
  3. Improves flexibility by shortening lead-times through processes (connected processes, smaller lot sizes). READ HERE.
  4. Improves scalability by making equipment that is efficient with smaller lot sizes. READ HERE.
  5. Reduces inventory by connecting processes and reducing lot sizes through quick changeover. READ HERE.
  6. Improves productivity by working on one thing at a time and cutting out wasted motion. READ HERE.
  7. Simplifies material replenishment by making the speed of material consumption steady and paced to a takt time. READ HERE.
  8. Frees up floor space by opening space used for inventory. READ HERE.
  9. Makes kaizen take root by exposing hidden problems and making them more visible. READ HERE.
  10. Improves morale by promoting cross-training and skill enhancement, as well as identifying and solving problems more quickly and reducing frustration. READ HERE.

Topper Industrial will use this blog to take a deep dive and look at this issue and benefits.

Fork Truck Free Benefit: Builds in quality.   When utilizing one-piece flow and Fork Truck Free, every worker is an inspector. One Piece Flow refers to the concept of moving one workpiece at a time between operations within a work cell. The opposite activity is to process an entire batch or lot at each operation before moving it to the next operation.

One Piece Flow keeps WIP (work in process) at the lowest possible level, encouraging work balance, better quality, and other internal improvements.  Each piece or lot is looked at by the next process (the customer) immediately, so defects are caught sooner. If defects are passed on, it is a very small batch.

One Piece Flow is a fundamental element of becoming lean. Processing one unit at a time may meet with resistance from manufacturing organization which live in the realm of batch manufacturing. The word “one” is not literal and may in fact be related to the customers’ requirements and could be one unit of order. In the lean construct, it does require a manufacturer to only process what the customer wants, in the quantity, and in the time needed.

Quantifying One Piece Flow, Quality and Fork Truck Free

By calculating the takt time for products all cycle times are either less than, or equal to, the takt time. This may involve many kaizen events to achieve but is essential. The starting point (current state of the Value Stream Map) will establish a benchmark to determine the efficacy of a future state which is Fork Truck Free.

Manufacturers must base the process capacity or equipment capacity on the takt time.  This initiates a Kanban pull system of working.

Instead of fork trucks throughout the plant, One Piece Flow ensures that the layout of a manufacturing plant supports Fork Truck Free as a quality improvement. Each layer of cellular manufacturing can be measured against the target of defect-free. There is no value in allowing the defect to permeate downstream manufacturing. The cost of scrap materials from defective batch manufacturing often exceed the profit margin to manufacture the product.

Topper Industrial ( is a leading manufacturer of material handling equipment. Topper provides lean material handling solutions to the supply chain.

Topper Industrial is able to engineer and design Industrial Carts (Mother / Daughter Cart Systems, Quad Steer Carts or Tracking Carts, Specialized Delivery Carts, Transfer Carts with Roller Deck, Static Carts, Rotation Carts, Tilt Carts or Kitting Carts), Industrial Cart Components (Parts Department), Industrial Containers (Corrugated and Wire Mesh Containers), PalletsLift/Tilt Systems, and Racking. Topper Industrial designs all products with ergonomics in mind, focusing on ease of use and best positioning of material to get the job done

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