This document discusses one piece flow/continuous flow manufacturing and cellular manufacturing. It defines cellular manufacturing as a production layout where equipment and workstations are arranged to facilitate continuous flow production with characteristics of small lot sizes and high frequency of style/model changes. Key benefits of cellular manufacturing include simplifying material flow and inter-department management, reducing production lead time and process time, simplifying scheduling, and allowing smaller lot sizes. Prerequisites for implementing one piece flow include having at least two connected processes, limiting and controlling work-in-process, using an andon system, implementing rapid response time, standardizing work, and having supervisors manage loading to packing as a single unit.

1. General Information
One Piece
Flow/Continuous
Flow

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Goal
Memahami PENTINGNYA
Penerapan Konsep One-Piece
Flow VS Proses Produksi
Tradisional

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Coach’s Background
AJI WIJAYA KUSUMA, ST
Enthusiast & professional on Lean,
Improvement, people development
and motivation.
16 years experience in Apparel
Industry focus on practical lean
implementation, costing & capacity
management
471.wijayakusuma@gmail.com
+62 815 7898 6913
Aji Wijaya Kusuma
Lean Manufacturing
Industrial Engineering
Production Planning
Apparel CMT Costing & CPM
90%
90%
80%
85%
85%
Supplier Capacity Management
https://www.youtube.com/user/471WijayaKusuma/featured
https://www.facebook.com/Lets-LEAN-788239307962079

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One Piece Flow/Continuous Flow adalah
hasil akhir dari berbagai inisiatif
improvement lainnya:
1. Mindset Kaizen
2. 5S & Visual Management
3. TPM
4. RFT
5. Pull System
6. Multi Skill Development
7. Standard Work
8. Line Balancing
9. A3 PDCA Problem Solving

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CELLULAR
MANUFACTURING

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CELLULAR MANUFACTURING
Definisi : Layout produksi manufaktur dimana
peralatan & stasiun kerja diatur sedemikian rupa untuk
memfasilitasi continuous-flow production (system
produksi mengalir) dengan karakteristik small lot,
frekuensi pergantian style/model tinggi
Karakteristik cell man: High skilled
workers(menguasai beberapa proses sekaligus)
membutuhkan quick response & feedback antar proses

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CELLULAR MANUFACTURING EXAMPLE

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CELLULAR MANUFACTURING LAYOUT EXAMPLE

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CELLULAR MANUFACTURING LAYOUT EXAMPLE

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1. Menyederhanakan aliran dan manajemen material
2. Mengurangi perjalanan lintas departemen-production leadtime (50% )
3. Mengurangi waktu proses (40%)
4. Mengurangi ukuran lot
5. Menyederhanakan penjadwalan
CELLULAR MANUFACTURING

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PRASYARAT ONE PIECE FLOW :
1. Minimal 2 proses terhubung(Loading,
sewing and finishing)
2.WIP/Penumpukan dibatasi/dikontrol
3.Sistem Andon
4.Raport Line (SQDC)
5.RFT
6.Standar Kerja
7.5S & Visual Management
8.Leader/Spv mengelola sebagai satu
kesatuan dari loading-packing

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22. Neal Creative ©
FINISH
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