Agile Factory

Lean Manufacturing - APICS discussion

Eight Conditions for Flow Production

From: Norman Bodek
Sent: February 21, 2005

I hope you liked my earlier series titled the 10 Commandments of Kaikaku by Hiroyuki Hirano.  I am working on his latest book, a difficult but fascinating process for me.  At Productivity Inc. – Press I published over a hundred books, training courses, manuals, etc. on JIT.  Each product was to enhance our knowledge of the Toyota Production System.  It was a privilege for me to meet and work with and publish the books of the great masters, Mr. Ohno and Dr. Shigeo.  Their books are classics.  Hirano adds to the master’s original thoughts from his practical application of JIT these past twenty years in Japan.   Editing and re-writing his new book is an amazing challenge for me.  I am moving towards publication in English as fast as I can.  Since I recently finished my latest book, All You Gotta Do Is Ask co-authored with Chuck Yorke, I have increased my time on the Hirano book and I am fascinated with Hirano’s ability to add to our practical knowledge base of JIT.

I hope you liked my first series and I thought that you might like to learn more about the book as I work on it.

In this new book Hirano has a part on the Eight Conditions for Flow Production·"one-piece flow".   As I did with the 10 Commandments I would like to share with you my understanding of these Eight Conditions and post them to you within the next few weeks.  The conditions are directly from Hirano, the comments are mine.  Please do let me know if you find this exercise of mine of value to you.


Mr. Hiroyuki Hirano has a consulting firm in Tokyo and has written many books on JIT.  At Productivity Press I published a few of his books including:
Jit Factory Revolution: A Pictorial Guide to Factory Design of the Future
Jit Implementation Manual: The Complete Guide to Just-In-Time Manufacturing (Everything You Need to Know for Eliminating Costly Waste)
5 Pillars of the Visual Workplace: The Sourcebook for 5s Implementation
5S for Operators: 5 Pillars of the Visual Workplace

His place in history is to be the first to fully organize and explain all the elements of JIT in an easy to understand format.   He also has been the leading thinker on the power of 5S.

I am now working on his latest book which will be published later this year.  He is an excellent consultant and frequently works with companies in Japan and India.  He is in India this week. I wish there were Americans who would realize the power of bringing him over here.

Best regards,

Norman Bodek


Eight Conditions for Flow Production

The 1st condition: Lay out facilities in the sequence of processes

The 2nd condition: Make facilities small and exclusive use

The 3rd condition:  Make U-shape line / parallel line

The 4th condition:  Working by standing

The 5th condition: Multi-process operation·multi-skill operator

The 6th condition: To bring up the degree of processing one by one

The 7th condition: Synchronization

The 8th condition: To make the flow