What is Pitch in Lean Manufacturing?

Pitch in Lean Manufacturing: Optimizing Workflow Efficiency

In the realm of lean manufacturing, pitch is a crucial concept that directly impacts the organisation of production processes and overall productivity. By focusing on the steady and efficient flow of work, pitch ensures that production stays aligned with customer demand, helping manufacturers avoid delays and maximise resource utilisation.

This blog will explore the concept of pitch in lean manufacturing, its calculation, and how it affects the production process.

What is Pitch?

Pitch refers to the rate at which a pacemaker process collects completed work and sets the pace for the rest of the production line. The pacemaker serves as the central point for production planning, dictating the rhythm of manufacturing. Essentially, pitch is a performance measure that synchronises production tempo with customer demand. It ensures that resources are used efficiently, and products are delivered on time, without overproduction or idle time.

By establishing a consistent pitch, manufacturers can control the flow of materials and labour, keeping the production process steady and in line with market needs.

The formula for calculating pitch is:

Pitch = Takt Time × Pack-out Quantity

Where:

• Takt Time represents the rate of customer demand, or the time required to produce one unit to meet customer needs.
• Pack-out Quantity refers to the number of units that fit in a standard container or batch.

Understanding Pitch Through Examples

Let’s break this down with a few examples:

Example 1:
Suppose the cycle time to complete one unit is 45 minutes, and a standard container holds 60 pieces. According to the formula, the pitch would be:

Pitch = 45 minutes × 1 = 45 minutes

In this case, every 45 minutes, the container would be filled, and production would continue at this rate to maintain efficiency.

Example 2:
Now, imagine that the cycle time is 1 minute per unit, and each container holds 20 pieces. Using the pitch formula:

Pitch = 1 minute × 20 = 20 minutes

This means that every 20 minutes, a fully packed container can be taken off the production line, ensuring that the process remains efficient and uninterrupted.

Role of the Water Spider (Mizusumashi)

In lean manufacturing, the Water Spider—also known as Mizusumashi—plays a crucial role in maintaining the pitch. The Water Spider is responsible for moving completed containers of products at designated intervals, such as the ones calculated in the examples above.

By taking completed containers at regular intervals, the Water Spider ensures that production workers can remain focused on their tasks without unnecessary interruptions. This helps to maintain a smooth flow on the production floor, preventing bottlenecks or downtime that could slow down the entire process.

Pitch Interval

The pitch interval is the period during which one product unit must be completed. It represents the frequency of the pitch over a given time. For example:

If the pitch is 20 minutes, and the total available work time for a shift is 240 minutes, then:

Pitch Interval = 240 minutes / 20 minutes = 12

This means there will be 12 pitch intervals during the shift, and within each interval, one product unit should be completed to maintain the ideal workflow pace.

Benefits of Using Pitch in Lean Manufacturing

• Synchronises Production with Demand:
  Pitch ensures that production is aligned with customer demand, preventing overproduction and minimising inventory build-up.
• Reduces Waste:
  By establishing a steady and predictable production flow, pitch helps to reduce waste associated with waiting times, excess inventory, and unnecessary movement of materials.
• Improves Workflow Efficiency:
  When pitch is properly calculated and followed, it allows for better resource utilisation and a more consistent workflow across the production line.
• Enhances Productivity:
  A well-maintained pitch allows companies to optimise their productivity by ensuring that workers and machines are operating at the most efficient rate to meet demand.

Conclusion

In lean manufacturing, pitch is a fundamental concept that helps streamline the production process by synchronising it with customer demand. By calculating and applying pitch, manufacturers can create a smooth, continuous workflow that eliminates waste, improves productivity, and ensures timely delivery of products.

Understanding and leveraging pitch enables businesses to optimise their operations, stay responsive to market changes, and maintain a competitive edge. Incorporating the principles of pitch into manufacturing can lead to more effective processes and better outcomes for both the company and its customers.