Implementation of Continuous Flow System in Manufacturing Operation

Abstract

The Continuous Flow System (CFS) is a production system that focuses on one piece flow product at every process in the assembly line. The implementation of this CFS could lead to operational excellence in terms of productivity, space utilization and the number of workers. CFS can be considered as a lean manufacturing foundation and its effective implementation promises significant savings in operation. CFS is achieved through a series of associated kaizen activities at the identified working place. The kaizen activities include establishment of Standardized Work (SW), implementation of U-shaped line and establishment of Material Handling System (MHS). All these activities are carried with one ultimate goal; to eliminate identified waste at the work place. This is essential to any CFS implementation. This paper presents a series of kaizen activities that have been engaged in creating the continuous flow system at the identified assembly line. This is a case-based study which was conducted at a local auto-component company in Malaysia. Findings from the results show that the company has achieved high productivity, minimal space utilization as well as reduction in number of direct manpower. The outcome of this CFS implementation confirms that it has met the supposedly lean principles also known as the one piece flow. Therefore, the objective of this study is to highlight the implemented kaizen activities and its benefit in achieving the CFS of the case study.