One-piece flow is rarely practical in process manufacturing—but it’s still a powerful target.
In his latest article for the Association for Supply Chain Management (ASCM), Peter King, Principal Business Consultant at Zinata, explores how manufacturers can use one-piece flow as a directional ideal—even if full implementation isn’t feasible.
Titled “Aim for One-Piece Flow Manufacturing to Advance Operations in Any Plant,” the article blends realism and aspiration to show how applying its principles can drive measurable improvements, even in complex or constrained environments.
A pragmatic approach to one-piece flow
King’s article tackles a critical challenge in manufacturing operations: While pure one-piece flow manufacturing is often impractical or impossible in process operations, it serves as an invaluable target for driving operational improvements. Rather than dismissing one-piece flow as irrelevant to process manufacturing, King advocates for using its principles as a directional guide to identify opportunities for improvement.
His pragmatic approach recognizes that most manufacturing environments — particularly process operations involving heat treating, chemical processing, or batch-dependent production — cannot literally implement one-piece flow. By aiming toward one-piece flow principles, however, manufacturers can identify specific actions and modifications that move them closer to this ideal, resulting in measurable improvements in efficiency, quality, and responsiveness.
Key benefits of one-piece flow implementation
The article highlights several critical advantages of adopting one-piece flow principles:
- Reduced lead times — By limiting work-in-progress inventory and producing goods just as they’re needed, products move seamlessly from one workstation to the next without delay. This can reduce lead times by 50-90%, enabling manufacturers to respond to customer orders much faster.
- Improved quality control — Unlike batch production where defects may affect entire lots before detection, one-piece flow allows for immediate identification and correction of quality issues, significantly reducing waste and rework.
- Enhanced flexibility — The system enables manufacturers to adapt quickly to changing customer demands and market conditions, supporting mass customization without the traditional penalties of increased complexity.
- Waste elimination — One-piece flow directly targets work-in-process inventory and other forms of manufacturing waste, creating leaner, more efficient operations.
Implementation considerations
King’s expertise shines through in his discussion of the practical aspects of implementing one-piece flow. The methodology requires careful consideration of cellular manufacturing layouts, standardized work processes, and pull production systems. Success depends on stable demand patterns, standardized processes, and a commitment to continuous improvement principles.
The article also addresses that while one-piece flow offers tremendous benefits, it may not be suitable for every manufacturing environment. Process manufacturing, heat-treating operations, and certain craft production methods may require different approaches to achieve optimal flow.
Ready to learn more about implementing one-piece flow in your operations?
Read Peter King’s complete article, “Aim for One-Piece Flow Manufacturing to Advance Operations in Any Plant,” on the Association for Supply Chain Management website.
For insights on how Zinata can help optimize your manufacturing operations, connect with our team of experts who bring decades of experience in operational excellence and lean manufacturing implementation.
About Peter King
Peter L. King, CSCP, is president of Lean Dynamics LLC and principal business consultant at Zinata Inc. Prior to founding Lean Dynamics, he spent 40 years with DuPont in a variety of manufacturing automation, project management and lean continuous improvement programs. He is the author of several books on lean, including Lean for the Process Industries (Productivity Press, 2009, 2019). Learn more about Peter King >>
