Lesson 2: Core Concepts
About This Lesson
Define flow, explain Little's Law conceptually, and address the HMLV misconception.
Video 1: What is Flow?
1 minWhich of the following are symptoms of batch-and-queue (poor flow)? Select all that apply.
Select 1-5 option
Video 2: Why WIP Kills Lead Time
2 minExplore: Flow and WIP Reduction
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How does flow work mechanically?
Flow is achieved by reducing batch sizes, eliminating queues between operations, and synchronizing work steps.
- Little's Law: Lead Time = WIP / Throughput. Reduce WIP to reduce lead time.
- Queue time typically accounts for 85-95% of total lead time in job shops.
- Batch size reduction is the primary lever - smaller batches mean shorter queues.
- Pull signals (like kanban) prevent overproduction and limit WIP automatically.
- Cellular layouts reduce transport between operations and enable tighter flow.
Understanding these mechanics lets you diagnose flow problems and identify which lever to pull.
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Video 3: Flow in High-Mix Low-Volume
2 minBatch Size Benefits
Match each action to its primary benefit for flow.
Cutting batch sizes from 50 to 10 units
Limiting the number of jobs released to the floor
Creating manufacturing cells for product families
Reducing setup time with quick-change tooling
Finding defects at the next operation instead of end inspection
Flow Vocabulary
Flip each card to learn the key terms for flow thinking.
Cards flipped: 0 / 8
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