<title>Continuous flow manufacturing</title>

Abstract

As competitive pressures continue to test the viability of every manufacturing enterprise, an ongoing program of operational improvement is essential. Continuous Flow Manufacturing (CFM) is a methodology created and practiced by IBM to meet this need. CFM combines the elements of total quality control, total people involvement and the elimination of waste to insure continuous attention to enhancements of manufacturing efficiency. This paper provides an overview of CFM and suggests six generic areas of every manufacturing line where the CFM approach can be used. The CFM methodology has been applied to an IBM internal business unit that manufactures photomasks used for semiconductor production. In 1984, serviceability and quality measurements in ths business unit were unacceptably low; and business measurements were nonexistent. CFM provided the framework for dramatic operational improvements in this business unit. Today, serviceability in the 90% to 100% range is routinely achieved. Delivery times have been more that cut in half, while superlative quality mesruements have been attained. Finally, cost reductions have been realized in an environment of ever-increasing technological challenge. Plans for future improvements using the CFM method are in place. The goal of all manufacturing endeavors has always been, and still is, ongoing operation improvement. CFM offers a structured methodology for pursuing this goal.© (1991) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.