ABSTRACT
Anything with an input that is transformed into something else representing the output is defined as a process. A process can also be information that is transformed into a different output by a particular input. Batching systems and processes and their resulting variations are the hidden enemies of Lean thinking. It is this batching mindset that makes sustaining the one-piece flow (OPF) philosophy so difficult. Batching systems are also known as push systems. Batching can be observed in all types of organizations; at restaurants, fast-food establishments, banks, insurance companies, government agencies, hospitals, airports, and even directing traffic. There are eight major forces that drive humans to batch. These are: brains, setups/changeovers, travel distance, equipment, processes, idle time, space, and variation. The practice of bringing in batches of product before they are needed ultimately requires more labor and space to handle all the extra demand throughout the system.
