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Achieving Continuous Flow

Achieving Continuous Flow (5 Days)

Breakaway Lean Workshop Series 1 2 3 4 5 6

Workshop Content

This five-day workshop develops knowledge and skills for implementing continuous flow in manufacturing and assembly processes. Participants will learn: how to conduct work element analysis, how to calculate takt times, how to create operator balance charts, how to evaluate and improve equipment layout and material presentation; and, how to plan and implement standard work methods to reduce the labor, material and facilities costs in manufacturing and assembly operations.

Who Should Attend

This workshop is intended for Lean/Six Sigma Black Belts responsible for planning, organizing and managing continuous improvement of manufacturing and assembly processes. This training is team-based training. Each team should include the Champion plus up to four Lean/Six Sigma Black Belts. There will be a maximum of three teams allowed per session.


Participants must have completed Champion Training with current and future state value stream maps designed prior to enrolling in this program.

Workshop Materials

Each participant will receive a Manual with all workshop materials included.

Workshop Goals

This workshop is intended to develop knowledge of the philosophy, process and tools for achieving continuous flow processing. This workshop will provide participants with the opportunity to practice the application of continuous flow processing in a live manufacturing or assembly process. This workshop will help participants to identify and quantify the cost savings from continuous flow processing projects.

Workshop Outline

  • Introduction to Continuous Flow Processing
  • Conducting the Process Analysis - Current State Performance Data
  • Constructing Operator Balance Charts
  • Analyzing the Current Layout and Material Flow
  • Performing Paper Kaizen
  • Considering the Role of Automation
  • Designing the Future State Layout and Material Flow
  • Determining the Cost Savings from Continuous Flow Processing
  • Planning & Deploying the Future State Cell Design
  • Developing Standard Work Methods and Charts
  • Executive Reports & Management Review Process

Breakaway Lean Workshop Series 1 2 3 4 5 6

To find out more about Omnex's workshops and consulting services in Breakaway Lean�, Excelerated Six Sigma� or Unified Lean/Six Sigma� please contact:

  Omnex Business Development


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