{"id":270,"date":"2006-12-04T10:40:06","date_gmt":"2006-12-04T17:40:06","guid":{"rendered":"https:\/\/staging.opexlearning.com\/resources\/270\/batch-and-queue-or-single-piece-flow"},"modified":"2020-09-06T19:42:22","modified_gmt":"2020-09-07T00:42:22","slug":"batch-and-queue-or-single-piece-flow","status":"publish","type":"post","link":"https:\/\/staging.opexlearning.com\/resources\/batch-and-queue-or-single-piece-flow\/270\/","title":{"rendered":"Batch-and-Queue or Single-Piece Flow in Peanut Butter and Jelly Sandwich Making"},"content":{"rendered":"<div class=\"a296a24fa2fc69ef5487857f02f111e8\" data-index=\"9\" style=\"float: none; margin:10px 0 10px 0; text-align:center;\">\n<script async src=\"\/\/pagead2.googlesyndication.com\/pagead\/js\/adsbygoogle.js\"><\/script>\r\n<!-- Single Post readerboard -->\r\n<ins class=\"adsbygoogle\"\r\n     style=\"display:inline-block;width:728px;height:90px\"\r\n     data-ad-client=\"ca-pub-8207522353004717\"\r\n     data-ad-slot=\"1144967431\"><\/ins>\r\n<script>\r\n(adsbygoogle = window.adsbygoogle || []).push({});\r\n<\/script>\n<\/div>\n<p>Batch-and-Queue or Single-Piece Flow in Peanut Butter and Jelly Sandwich Making. Having as<a title=\"about pete abilla family\" href=\"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/\"> large of a family as mine<\/a>, we need all of our internal processes optimized. You know what I mean?<\/p>\n<p>To be able to effectively manage a large family, we run on a pretty strict routine &#8212; I didn&#8217;t say &#8220;schedule&#8221; here because our family operation is also very flexible and agile. But, we have a routine and we, for the most part, stick to it. One routine is that I make the kids&#8217; lunches every night for school the next day.<\/p>\n<p>During one late evening last week while making peanut butter and jelly sandwiches (PB &amp; J), I noticed that this was an opportunity to test batch-and-queue versus one-piece flow.<\/p>\n<div align=\"center\">\r\n<table cellpadding=\"0\" style=\"width: 819px;\">\r\n<tbody>\r\n<tr>\r\n<td style=\"width: 228px;\">\r\n<ul>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-lean\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-lean\/', 'What is Lean?');\" title=\"what is lean manufacturing or lean management?\">What is Lean?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-heijunka\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-heijunka\/', 'What is Heijunka?');\" title=\"what is heijunka in lean manufacturing\">What is Heijunka?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-andon-in-the-toyota-production-system\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-andon-in-the-toyota-production-system\/', 'What is Andon cord?');\" title=\"what is andon in lean manufacturing and the toyota production system\">What is Andon cord?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-poka-yoke\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-poka-yoke\/', 'What is Poka Yoke?');\" title=\"define poka yoke\">What is Poka Yoke?<\/a><\/li>\r\n<li><a href=\"\/?s=kaizen\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/?s=kaizen', 'What is Kaizen?');\" title=\"what is kaizen in lean manufacturing and the toyota production system\">What is Kaizen?<\/a><\/li>\r\n<li><a href=\"\/resources\/batch-and-queue-or-single-piece-flow\/270\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/batch-and-queue-or-single-piece-flow\/270\/', 'What is One Piece Flow?');\" title=\"what is one piece flow, single piece flow in lean manufacturing\">What is One Piece Flow?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-kanban\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-kanban\/', 'What is Kanban?');\" title=\"what is kanban in lean manufacturing\">What is Kanban?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-push-vs-pull-strategy\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-push-vs-pull-strategy\/', 'What is Pull versus Push?');\" title=\"what is push vs pull strategy?\">What is Pull versus Push?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-just-in-time-manufacturing\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-just-in-time-manufacturing\/', 'What is Just in Time?');\" title=\"what is just in time manufacturing in lean production\">What is Just in Time?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-smed-and-quick-changeover\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-smed-and-quick-changeover\/', 'What is SMED?');\" title=\"what is smed, single minute exchange of dies, and quick changeover in lean manufacturing\">What is SMED?<\/a><\/li>\r\n<li><a href=\"\/resources\/the-toyota-a3-report\/363\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/the-toyota-a3-report\/363\/', 'What is a Toyota A3 Report?');\" title=\"what is toyota a3 report in lean manufacturing?\">What is a Toyota A3 Report?<\/a><\/li>\r\n<li><a href=\"\/resources\/5s\/180\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/5s\/180\/', 'What is 5S?');\" title=\"what is 5S in lean manufacturing and the toyota production system\">What is 5S?<\/a><\/li>\r\n<li><a href=\"\/resources\/manage-for-daily-improvement-lean-manufacturing-system\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/manage-for-daily-improvement-lean-manufacturing-system\/', 'What is Shop Floor Management?');\" title=\"what is lean shop floor management all about?\">What is Shop Floor<br \/>Management?<\/a><\/li>\r\n<li><a href=\"\/resources\/what-is-kata-process-improvement\/22073\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/what-is-kata-process-improvement\/22073\/', 'What is Kata?');\" title=\"What is Improvement Kata?\">What is Kata?<\/a><\/li>\r\n<li><a href=\"\/resources\/the-theory-of-constraints-the-fundamentals\/2632\/\">What is the Theory of Constraints (TOC)?<\/a><\/li>\r\n<\/ul>\r\n<\/td>\r\n<td style=\"width: 337px;\">\r\n<p style=\"text-align: center;\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-15757 size-full\" src=\"https:\/\/staging.opexlearning.com\/resources\/wp-content\/uploads\/2014\/11\/toyota-house-production-system-lean.gif\" alt=\"the toyota house, lean manufacturing\" width=\"400\" height=\"379\" \/><\/p>\r\n<\/td>\r\n<td style=\"width: 254px;\">\r\n<ul>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-lean-leadership\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-lean-leadership\/', 'What is Lean Leadership?');\" title=\"what does lean leadership mean?\">What is Lean Leadership?<\/a><\/li>\r\n<li><a href=\"\/resources\/respect-for-people-principle-lean-management\/14553\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/respect-for-people-principle-lean-management\/14553\/', 'What is Respect for People?');\" title=\"what is respect for people in lean manufacturing\">What is Respect for People?<\/a><\/li>\r\n<li><a href=\"\/resources\/root-cause-analysis\/172\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/root-cause-analysis\/172\/', 'What is the 5 Whys?');\" title=\"what are the 5 whys and root cause analysis in lean manufacturing\">What is the 5 Whys?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-takt-time\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-takt-time\/', 'What is Takt Time?');\" title=\"What is Takt Time in the Toyota Production System?\">What is Takt Time?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-gemba-and-gemba-walk\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-gemba-and-gemba-walk\/', 'What is Gemba?');\" title=\"what is gemba? what is a gemba walk?\">What is Gemba?<\/a><\/li>\r\n<li><a href=\"\/resources\/genchi-genbutsu-go-and-see-part-1\/2896\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/genchi-genbutsu-go-and-see-part-1\/2896\/', 'What is Genchi Genbutsu?');\" title=\"genchi genbutsu, go and see, lean manufacturing\">What is Genchi Genbutsu?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-standard-work\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-standard-work\/', 'What is Standard Work?');\" title=\"what is standard work or standardized work in the toyota production system?\">What is Standard Work?<\/a><\/li>\r\n<li><a href=\"\/resources\/pdca-cycle-or-pdsa-cycle-which-is-right\/13653\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/pdca-cycle-or-pdsa-cycle-which-is-right\/13653\/', 'What is Plan-Do-Check-Act?');\" title=\"what is PDCA in lean manufacturing and the toyota production system\">What is Plan-Do-Check-Act?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-value-stream-mapping\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-value-stream-mapping\/', 'What is Value Stream Mapping?');\" title=\"what is value stream mapping and its benefits\">What is Value Stream Mapping?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-visual-management\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-visual-management\/', 'What is Visual Management?');\" title=\"what is visual management in lean manufacturing\">What is Visual Management?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-mura-muri-muda\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-mura-muri-muda\/', 'What is Mura, Muri, Muda?');\" title=\"what is mura, muri, muda in toyota production system?\">What is Mura, Muri, Muda?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-jidoka\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-jidoka\/', 'What is Jidoka?');\" title=\"what is jidoka in lean manufacturing\">What is Jidoka?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-hoshin-kanri-in-lean-manufacturing\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-hoshin-kanri-in-lean-manufacturing\/', 'What is Hoshin Kanri?');\" title=\"what is hoshin kanri in lean manufacturing\">What is Hoshin Kanri?<\/a><\/li>\r\n<li><a href=\"\/resources\/?s=lean+startup\">What is Lean Startup?<\/a><\/li>\r\n<li><a href=\"\/resources\/what-is-the-role-of-the-waterspider-in-lean-manufacturing\/22565\/\">What is a Water Spider?<\/a><\/li>\r\n<li><a href=\"\/resources\/what-is-cellular-manufacturing\/23483\/\">What is Cellular Manufacturing?<\/a><\/li>\r\n<\/ul>\r\n<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/div>\n<h2><strong>One-Piece Flow<\/strong><\/h2>\n<p><a title=\"single piece flow example\" href=\"https:\/\/staging.opexlearning.com\/resources\/most-interesting-lean-guy-world-single-piece-flow\/10160\/\">One-Piece Flow<\/a> comes from the Toyota Production System, anglicized in the United States as Lean Manufacturing. One-Piece Flow is also known by various other names such as the following:<\/p>\n<ol>\n<li>One-piece Flow<\/li>\n<li>Make-one, Move-one<\/li>\n<li>Single-piece Flow<\/li>\n<li>Continuous Flow<\/li>\n<li>Flow Manufacturing<\/li>\n<\/ol>\n<p>TPS emphasizes right-sizing your batches because batches that aren&#8217;t the right size leads to queues, which leads to waiting time, which leads to poor space or resource utilization, increased <a title=\"shmula.com, wip, work in process, queueing theory,product development\" href=\"https:\/\/staging.opexlearning.com\/resources\/littles-law-for-product-development\/263\/\">Work-in-Process (WIP) or Things-in-Process (TIP)<\/a>, longer cycle times, which are all forms of <a title=\"what is waste in the toyota production system\" href=\"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/what-is-mura-muri-muda\/\">wastes or muda<\/a>.<\/p>\n<p>On the other hand, the Batch-and-Queue approach teaches us to build stuff, let it queue in front of the next step, all throughout the system. Batch-and-Queue systems lead to poor space utilization because of the batches of work waiting to be served that take up space on the production floor, longer cycle times, a higher probability of defects because you build stuff and let it sit and, lower morale because batch-and-queue leads to large sizes of work-in-process, not finished goods &#8212; the psychological message is that you&#8217;ve created a bunch of unfinished stuff, further burdening the team with thoughts of &#8220;man, we have so much more to do.&#8221;<\/p>\n<h3><strong>Peanut Butter Sandwiches, One-Piece Flow<\/strong><\/h3>\n<p>There are two ways to build sandwiches &#8212; the Batch-and-Queue method or the One-Piece Flow method.<\/p>\n<ul>\n<li>Batch-and-Queue: To build sandwiches the Batch-and-Queue style I would take 3 pieces of bread (3 lunches to make) and place peanut butter on it. Then, let the 3 pieces of bread with peanut butter sit, while I take 3 pieces of bread and place jelly on it. Then, I&#8217;d marry the two sides of the bread and be done with 3 sandwiches.<\/li>\n<li>Single-Piece Flow: For Single-Piece Flow, I&#8217;d take one piece of bread place peanut butter on it, then take one piece of bread and place jelly on it, and then marry them. I would do this 3 times.<\/li>\n<\/ul>\n<div style=\"text-align: center;\"><img loading=\"lazy\" decoding=\"async\" class=\"alignright size-medium wp-image-15846\" src=\"https:\/\/staging.opexlearning.com\/resources\/wp-content\/uploads\/2006\/12\/single-piece-flow-example-225x300.jpg\" alt=\"single piece flow example in lean manufacturing\" width=\"225\" height=\"300\" srcset=\"https:\/\/staging.opexlearning.com\/resources\/wp-content\/uploads\/2006\/12\/single-piece-flow-example-225x300.jpg 225w, https:\/\/staging.opexlearning.com\/resources\/wp-content\/uploads\/2006\/12\/single-piece-flow-example.jpg 375w\" sizes=\"(max-width: 225px) 100vw, 225px\" \/><\/div>\n<p><!--adsense#468x60centerbanner--><\/p>\n<p>Single-Piece Flow approach is much better because there&#8217;s no waiting involved, cycle time is shorter because I&#8217;m completing sandwiches at each motion, and I feel better because I can visually see what I have completed.<\/p>\n<h2><strong>One-Piece Flow and Other Processes<\/strong><\/h2>\n<p>One-Piece Flow can be applied to many other processes. Here are a few examples:<\/p>\n<ul>\n<li>Software: Most software is built modularly &#8212; that is, in small modules, where one class can consumes or uses the services of another module. Ideally, modular code is of the right size such that the engineer can build each module to completion including dependent modules, instead of building several modules in parallel, leading to task-switching, which is a waste.<\/li>\n<li>Software Requirements: Requirements documents are historically chubby, batchy documents. a one-piece flow approach is to follow the Agile method by creating user stories, sizing them by effort and prioritizing them, then unpacking each story into atomic units we call &#8220;tasks&#8221; with time attached to it. Each tasks represents the take-one put-one approach and forces continuous flow in software development. Joel (Joelprah) talks about task-switching for software and simulated the huge <a title=\"shmula.com, task switching\" href=\"http:\/\/www.joelonsoftware.com\/articles\/fog0000000022.html\" target=\"_blank\" rel=\"noopener noreferrer\">negative impact it has on productivity<\/a>.\u00a0 The one-piece flow approach embraces iterative development and rejects the Waterfall approach, which is akin to Batch-and-Queue.<\/li>\n<li>Order Fulfillment: At Amazon it was mandatory to complete an order at a time, instead of several orders at a time. The associates had a difficult time understanding this concept until we showed them that the batch-and-queue approach leads to &#8220;switcheroos&#8221; &#8212; that is, mistakenly putting an item in the wrong order. The one-piece flow approach avoided this defect altogether and led to shorter cycle times, enabling the order to meet shipping deadlines.<\/li>\n<\/ul>\n<p>There are many, many other processes where you can employ the principle of One-Piece Flow. A few things to keep in mind before employing One-piece flow:<\/p>\n<ul>\n<li>Process must be highly capable of consistently producing high-quality product. If there are serious and consistent quality issues, then one-piece flow will be difficult to implement.<\/li>\n<li>Process must be repeatable.<\/li>\n<li>Where equipment is involved, uptime should be close to 100%, otherwise interruptions will disrupt flow.<\/li>\n<\/ul>\n<p>Today, take a look at the processes around you. In what ways can you implement one-piece flow in your environment?<\/p>\n<div align=\"center\"><iframe loading=\"lazy\" width=\"820\" height=\"615\" src=\"\/\/player.vimeo.com\/video\/111494050\" frameborder=\"0\" allowfullscreen=\"allowfullscreen\"><\/iframe><\/div>\n<!--CusAds0-->\n<div style=\"font-size: 0px; height: 0px; line-height: 0px; margin: 0; padding: 0; clear: both;\"><\/div>","protected":false},"excerpt":{"rendered":"<p>Batch-and-Queue or Single-Piece Flow in Peanut Butter and Jelly Sandwich Making. Having as large of a family as mine, we need all of our internal processes optimized. You know what I mean? To be able to effectively manage a large family, we run on a pretty strict routine &#8212; I didn&#8217;t say &#8220;schedule&#8221; here because [&hellip;]<\/p>\n","protected":false},"author":12327,"featured_media":8627,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"categories":[16],"tags":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v23.0 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Single Piece Flow - an Example<\/title>\n<meta name=\"description\" content=\"an explanation of single piece flow, one piece flow, a lean six sigma tool\" \/>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Single Piece Flow - 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