How to Create a Product Quantity / Product Routing Matrix

The first step before value stream mapping a Process is to make sure you have people involved that understand the process and the steps within. This may not be an issue for realatively simple to understand processes but many manufacturing processes have complexity to them and optimizing these more complex sub-process steps may actually be the big hitter in overall improvements.
Second, single piece flow in manufacturing is actually not the way to go. Its wrong. It was a result of VSM’s created from people not understanding the complexity within processes particularly where equipment, multifunctional electromechanical and/or chemical reactions are being performed.
Single Piece flow is for low flexible volume manufacturing.

Flexible Batch processing is the actual correct way to produce most modern manufacturing products. Each work cell will have the right size batch in order to pull from the downstream process at an economical level depending on all cost factors from raw material ordering to product delivery.

Also, flexible batches include batches of size = 1.

Batch control is the state of the art methodology and it is actually somewhat of a misnomer today as it spans single piece flow to continuous processes of mega size. Why the name then – it is related to the control philosophy and evolution of process control methods and software over the last 30 years — thus predating most quality efforts. It was often the one place in a plant where one could walk in and see SPC charts predicting precise outcomes hanging over a piece of equipment right sized for its production volumes. Intelligent science and engineering together with model predictive control methods were used. These would be similar to Robust Design today with all CTQ’s or KPIV and KPOV’s controlled and verified in real time.

Unfortunately these processes have continued to get better and better without tooting their horn because they were often running at very high 98 to 99+% efficiencies 24/7/365 and without large problems to solve not much noise was made.

You will here more about these high end process control methods as the US if not the world appears to be on the verge of Generation III of manufacturing improvement. Six-Sigma and Lean are great tools but there is an over-application and misapplication of the LEAN tools — but in a good way — every new improvement method now days is being called LEAN. Its not bad, but mislabelling can lead to confusion. What may be happening is the prolific use and common language created by LSS methods may be driving enough common acceptance of the underlying improvement tool attached to “LEAN” that it is being tried and used. The actual underlying foundation for improvement in any area is deep knowledge and wisdom. In manufacturing that foundation is primarily in science and engineering at the shop floor but supported by transaction based and business logic based support from the service and management levels. Thus is one is talking about a LSS project on improving a semiautomated manufacturing process that uses people, machines, computers, people, mechancial and chemical transformation steps then the science and engineering tools all impact the creation of knowledge and wisdom contained within these processes. Lean evolved as a nice almost common sense improvement one can do Once one’s processes were understood and controlled. Six-Sigma evolved as a 2-dimensional slice of the spehere of science and engineering used to create most manufacturing processes. Science and engineering are one sphere of intersecting spheres of influence necessary to complete a whole business system.

So keep your perspective and grow the wisdom seeking out and bringing in knowledge and using methods from all the spheres of influence to perfect manufacturing in our Phase III – 21st century manufacturing.