An ontology for flow thinking based on decoupling points – unravelling a control logic for lean thinking

ABSTRACT Continuous flow is the guiding star for lean thinking and considered the ideal state for value streams. Despite this objective, it is seldom possible to obtain a state of continuous flow in a wider context. Decision makers face dynamic environments, and variable internal preconditions require a flow-thinking approach that provides support in response to these challenges. In the present study, the underlying logic of flow thinking is first identified as the key management layer, and thereafter the effectiveness of flow is targeted. The vision of continuous flow is challenged by different exogenous requirements that result in flow discontinuities. Flow thinking is then used to identify 10 decision categories based on these discontinuities, each related to a type of decoupling point and classified as time-based (exogenous) or conversion-based (endogenous). The flow-thinking approach is finally applied in three different contexts: a time-phased product structure, a modularized approach for planning and control, and a mixed-model value stream.

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