ABSTRACT
In a manufacturing flow process, products or parts are made by going through the same set of operations, in the same sequence. Takt Time Grouping (TTG) was created when one of the authors, in the role of a consultant, was working with a mid-size manufacturing company to implement flow manufacturing. The first product to be manufactured in a flow process, brass and Teflon piston discs of different sizes, required primarily machining operations, with a few assembly operations. TTG sizing algorithm creates a smooth and even flow of transfer batches, which are moved in kanban bins through the flow process. When using kanbans in a flow process, the designer has an important trade off. Another consideration for placing kanban bins is protecting against disruptions due to set-up or downtime. Not surprisingly, in terms of work-in-process inventory level and flowtime, one-piece flow was the clear winner. TTG provides several benefits as a flow process control method.
