Single Piece Flow is the most efficient method to deliver a product or service to a customer. However, it is not usually possible to design a Value Stream in which product flows from raw material all the way to the customer. Pull systems are required to connect areas of Flow.

Linking Flow: FIFO, Kanban & CONWIP is a two-day intermediate level Lean Solution that teaches participants the principles of Pull. Through classroom work, participants will learn why Single Piece Flow is typically not feasible throughout the entire Value Stream. They will learn that issues such as changeover, machine breakdown and quality problems can be accommodated with controlled amounts of inventory and that these inventory control systems can also be used to schedule the production of upstream process, thereby eliminating the need to schedule multiple points in the value stream.

There are several different ways to connect areas of Flow, the most well known of which is probably Kanban, which is a type of supermarket pull system. Workshop participants will engage in a Kanban simulation that will demonstrate the power of this Lean tool to both control inventory levels and schedule upstream production. Participants will also learn about FIFO (First-In, First-Out), which is actually a type of Flow that uses small amounts of inventory to allow for disruptions to flow, such as changeover, machine breakdown and differences in cycle times. Finally, participants will learn about CONWIP. Whereas kanban controls inventory between processes, CONWIP is a system to control the level of inventory throughout the entire value stream. This workshop will teach participants to calculate the amount of inventory required between processes, as well as techniques to further reduce this inventory amount
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Linking Flow: FIFO, Kanban &CONWIP is considered an intermediate level Lean Solution because it typically is used to connect areas of Single Piece Flow. It is also useful to understand the concepts of Quick Changeover before implementing Pull, although this is not necessary.

Like most Lean Solutions workshops, Linking Flow: FIFO, Kanban & CONWIP combines classroom theory with practical exercises and a case study simulation to reinforce the training. During the simulation participants are assigned departments within a mock facility and must try to satisfy the next process with minimal amounts of inventory. They will then be assigned an area within your facility in which they will connect areas of Flow within your facility with the assistance of a Lean Solutions facilitator.

• Introduce the concept of Pull
• Demonstrate the benefits of Pull using a Kanban simulation
• Learn how to calculate inventory requirements
• Show several types of Pull systems
• Connect areas of Flow within your facility
• Create a plan to further reduce the inventory within the Pull system

Day One

• Introduction to Pull
• Creating a Supermarket Pull System
• Case Study: Kanban Simulation
• FIFO Lanes=

• Supermarkets
• CONWIP
• Exercise: Connecting Flow
• Workshop Summary

Workshop participants will be able to apply the principles of Linking Flow: FIFO, Kanban & CONWIP to any area of your organization. As a result, your value streams will require scheduling to occur at only one process; the rest will controlled by Pull and Flow. Inventory levels will be reduced while simultaneously increasing on-time delivery to the customer. Lead time will be dramatically reduced, because process will only produce according to actual customer consumption (as opposed to an anticipated demand). As a result, your value stream will be able to quickly adjust to changes in customer demand.

This workshop is great for operators, managers, supervisors, team leaders, quality employees, engineers, and material handling and logistics employees. An ideal team consists of a sample from each of these areas.

This is an intermediate level workshop and typically is implemented to connect areas Single Piece Flow. However, not all organizations are able to apply Flow, so the actual sequence of when Linking Flow: FIFO, Kanban & CONWIP is implemented depends heavily upon your company's Future State Implementation Plan. Most attendees should have significant prior Lean knowledge including concepts such as takt time, lead time, pull, flow, etc. If Lean is new to your organization, consider starting your Lean journey with either Launching the Lean Initiative or Lean Principles.

As with all our workshops, each participant receives their own workshop binder so they can keep their own notes for reference once the workshop is over. Participants also receive a Certificate of Completion to show that they have completed a Lean Solutions workshop.

The materials from the workshop may be redistributed within the company. Many organizations choose to hold short training sessions using these materials prior to implementing Linking Flow: FIFO, Kanban & CONWIP in a new area in order to train the employees in the concepts of Pull and to highlight their role in using the system. Additional workbooks are also available (call for pricing).

You also receive a 100% guarantee! If you are not satisfied either with the material covered or the teaching style of the workshop facilitator, there will be no charge! If we fail to meet your expectations, the only thing you will be asked to pay for will be the expenses incurred.

Although our workshops are designed to give the knowledge to you and your team, follow-up days are recommended to review progress made following each workshop. Typical organizations require one to two follow-up days about 2-4 weeks following the workshop. These follow-up days also help to ensure that the principles learned during the workshop are not forgotten or neglected after the workshop is over. If you are interested in a greater involvement by one of our expert facilitators, check out our On-Site Lean Implementation solution.

The base cost for this two-day workshop is $7,000, which covers the first 15 participants. Classes larger than 15 participants will be taught by two facilitators and cost $11,000. In order to keep the class size manageable and to facilitate the learning process, Lean Solutions restricts the maximum class size to 30 participants. Follow-up days cost $1,500-$2,000 per day, depending upon the experience of the facilitator. There is a 10% discount available for long-term engagements. Expenses are in addition to the costs outlined above and include cost of travel and accommodation (if required) as well as meals and workbooks ($20 per participant).

Lean Solutions will tailor workshops to meet each company's requirements. Call or e-mail for more information or to schedule a workshop.