Are You Keeping The Line Wet?

Last week, during a Gemba Academy Lean Bootcamp, Ron Pereira talked about “keeping the line wet” when teaching. This was a new term to me, but I found it to be an important term.

“Keep the line wet” is a phrase often used by anglers and fishermen, meaning to keep fishing continuously or to stay active in the pursuit of catching fish. The idea is that the more your fishing line is in the water, the better your chances of catching something. Metaphorically, it can be applied to other activities, suggesting that one should keep working or stay engaged in their efforts to achieve a goal.

In a manufacturing context, “keep the line wet” typically means to keep the production line running continuously, avoiding downtime or delays. It emphasizes the importance of maintaining a steady flow of operations, ensuring that machines and processes are always active to maximize productivity and efficiency. Just as in fishing, where keeping the line in the water increases the chances of success, in manufacturing, keeping the production line moving minimizes waste, reduces costs, and increases output.

“Keeping the line wet” in the context of manufacturing and one-piece flow can include ensuring that at least one instance of your product is completed before the production line goes on a break.

In one-piece flow, the goal is to move a single product through each step of the production process without interruption, rather than processing batches of products at each stage. To “keep the line wet” in this context means to maintain continuous movement and avoid stoppages.

Therefore, before taking a break, it’s important to ensure that a product completes its journey through the line so there’s no interruption in the flow. This minimizes the risk of bottlenecks and ensures that the line can resume smoothly after the break. It also helps to maintain efficiency and reduce the time wasted in restarting the production process after an interruption.

Keeping the line wet in manufacturing is crucial for several reasons:

1. Maximizing Efficiency: Continuous operation of the production line ensures that the manufacturing process runs at optimal efficiency. Stopping and starting the line can introduce inefficiencies, such as time lost in restarting machines, reorienting workers, or recalibrating processes.
2. Reducing Downtime: Frequent stops in production can lead to increased downtime, which is costly. Keeping the line wet helps minimize unplanned interruptions, ensuring that production targets are met and resources are used effectively.
3. Improving Throughput: A production line that runs continuously can produce more units in a given period. This increases overall throughput, which is essential for meeting demand, fulfilling orders on time, and maximizing revenue.
4. Maintaining Product Quality: Consistent operation helps maintain uniform product quality. Interruptions can lead to variations in process conditions (e.g., temperature, pressure), which may affect the final product’s quality. Continuous flow helps ensure that every product meets the same quality standards.
5. Reducing Waste: Stopping the line can result in material waste, especially if materials need to be discarded due to process interruptions. Keeping the line wet helps reduce material waste, improving overall resource efficiency.
6. Enhancing Worker Productivity: Workers tend to be more productive when they are engaged in a continuous flow of work. Frequent stops can disrupt focus and rhythm, leading to lower productivity. A steady workflow helps maintain high levels of worker engagement and productivity.
7. Meeting Customer Demand: Continuous production helps ensure that products are available when customers need them. This is particularly important in industries with tight delivery schedules or where delays could result in lost sales or customer dissatisfaction.
8. Lowering Costs: By keeping the line wet, manufacturers can lower operational costs associated with energy consumption, equipment wear and tear, and labor. For instance, machines operating continuously may consume less energy overall compared to frequent stops and starts, which often require more power to ramp back up.
9. Enabling Predictable Output: Consistent operation leads to predictable output levels, which is important for planning and scheduling. It allows better coordination with downstream processes, such as packaging, shipping, and inventory management.
10. Supporting Continuous Improvement: Continuous operation allows for better data collection on process performance. This data can be used to identify areas for improvement, optimize processes, and implement lean manufacturing principles more effectively.

To “keep the line wet” in manufacturing, you need to ensure that the production line operates continuously and efficiently with minimal downtime. Here are some strategies to achieve this:

1. Preventive Maintenance: Regularly schedule maintenance checks to prevent unexpected machine breakdowns. This includes lubricating parts, replacing worn components, and ensuring all equipment is functioning correctly.
2. Efficient Workflow Design: Design the production line to minimize bottlenecks. Ensure that each step in the process flows smoothly into the next, with minimal waiting times between stages.
3. Inventory Management: Maintain an adequate inventory of raw materials and components to avoid production halts due to shortages. Implement just-in-time (JIT) inventory systems to keep supplies flowing in sync with production needs.
4. Skilled Workforce: Ensure that your workers are well-trained and capable of handling different tasks. Cross-training employees can help fill gaps when someone is absent or when the workload shifts.
5. Automation: Use automation and robotics to handle repetitive tasks, which can increase speed and consistency, reducing the risk of human error that could cause delays.
6. Real-Time Monitoring: Implement real-time monitoring systems that provide instant feedback on production status. This allows for quick identification and resolution of issues that could disrupt the line.
7. Quality Control: Integrate quality checks at various stages of production to catch defects early. This prevents the need to stop the line for rework or adjustments later in the process.
8. Lean Manufacturing Principles: Adopt lean manufacturing principles to eliminate waste, streamline processes, and improve overall efficiency. This can include practices like 5S (Sort, Set in order, Shine, Standardize, Sustain) and Kaizen (continuous improvement).
9. Effective Communication: Ensure clear communication between all departments (e.g., production, maintenance, quality control, and supply chain). Quick information flow helps in addressing potential issues before they impact the production line.
10. Flexible Scheduling: Use flexible shift patterns or on-call teams to address sudden increases in demand or unforeseen disruptions, keeping the production line moving.

Keeping the line wet is vital for maintaining a smooth, efficient, and cost-effective manufacturing process. It helps ensure that production goals are met while maintaining high quality, minimizing waste, and keeping costs under control. By implementing these strategies, you can effectively “keep the line wet” in a manufacturing context, maintaining continuous production and maximizing efficiency.

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