{"id":26348,"date":"2021-05-31T11:23:36","date_gmt":"2021-05-31T15:23:36","guid":{"rendered":"https:\/\/www.flexpipeinc.com\/?p=26348"},"modified":"2025-09-10T14:00:59","modified_gmt":"2025-09-10T18:00:59","slug":"circular-manufacturing-the-rules-of-the-circle","status":"publish","type":"post","link":"https:\/\/www.flexpipeinc.com\/us_en\/circular-manufacturing-the-rules-of-the-circle\/","title":{"rendered":"Circular manufacturing: The rules of the circle"},"content":{"rendered":"<p>Circular manufacturing is a system for <strong>maximizing efficiency<\/strong> and <strong>reducing waste<\/strong> in a manufacturing site.<\/p>\n<p>In this video, Robert Simonis, principal consultant at KCE Consulting, explains the <a href=\"https:\/\/www.industryweek.com\/operations\/continuous-improvement\/article\/21985229\/rules-of-the-circle-visualizing-flow\" target=\"_blank\" rel=\"noopener\">four rules<\/a> of this lean technique and how they can <a href=\"https:\/\/online.kettering.edu\/news\/2016\/07\/07\/understanding-principle-flow-lean-manufacturing\" target=\"_blank\" rel=\"noopener\">improve the flow<\/a> of any work process.<\/p>\n<p><iframe loading=\"lazy\" src=\"https:\/\/vregisflexpipe.github.io\/video\/circular-manufacturing\/es\/\" width=\"100%\" height=\"800\"><span data-mce-type=\"bookmark\" style=\"display: inline-block; width: 0px; overflow: hidden; line-height: 0;\" class=\"mce_SELRES_start\">\ufeff<\/span><\/iframe><\/p>\n<h2>Rule No.\u00a01: The process should begin and end in the same location<\/h2>\n<p>For optimal flow, the <strong>work process should always end near the spot where it began<\/strong>. This ensures that as soon as an employee finishes a task, they can start the next one without wasting any time travelling from one end of the warehouse to the other. This usually means that the process will be laid out in a <a href=\"https:\/\/industrytoday.com\/lean-manufacturing-implementing-u-shaped-cells\/\" target=\"_blank\" rel=\"noopener\">U\u00a0shape<\/a>.<\/p>\n<figure id=\"attachment_26416\" aria-describedby=\"caption-attachment-26416\" style=\"width: 615px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-26416 size-full\" title=\"People on the production line, the workstations, and the equipment should be organized to optimize the flow and minimize waste so that productivity can be maximized. Source: Assembly Mag and Bosch Rexroth Corp\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/asb0312layout41.jpg\" alt=\"People on the production line, the workstations, and the equipment should be organized to optimize the flow and minimize waste so that productivity can be maximized. Source: Assembly Mag and Bosch Rexroth Corp\" width=\"615\" height=\"350\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/asb0312layout41.jpg 615w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/asb0312layout41-375x213.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/asb0312layout41-24x14.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/asb0312layout41-36x20.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/asb0312layout41-48x27.jpg 48w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><figcaption id=\"caption-attachment-26416\" class=\"wp-caption-text\">People on the production line, the workstations, and the equipment should be organized to optimize the flow and minimize waste so that productivity can be maximized. Source: Assembly Mag and Bosch Rexroth Corp<\/figcaption><\/figure>\n<p>By contrast, a <strong>process that follows a straight line<\/strong>\u2014while it might seem logical for the flow of materials\u2014<strong>forces operators and material handlers to make a return trip to their starting point at the end of each cycle<\/strong>, which is a form of <a href=\"https:\/\/theleanway.net\/The-8-Wastes-of-Lean\" target=\"_blank\" rel=\"noopener\">waste<\/a>.<\/p>\n<h2>Rule No.\u00a02: The process should not intersect<\/h2>\n<p>When a process starts and ends in the same location, there\u2019s a risk that people or materials will cross paths somewhere along the line. It\u2019s important to make sure that doesn\u2019t happen, as much for efficiency as for <a href=\"https:\/\/reverscore.com\/lean-safety\/\" target=\"_blank\" rel=\"noopener\">safety<\/a> reasons.<\/p>\n<figure id=\"attachment_26398\" aria-describedby=\"caption-attachment-26398\" style=\"width: 1875px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-26398 size-full\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore.png\" alt=\"Material handlers travel the width of the building, then return empty. Source: Robert Simonis\" width=\"1875\" height=\"1051\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore.png 1875w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-768x430.png 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-1536x861.png 1536w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-375x210.png 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-1024x574.png 1024w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-1280x717.png 1280w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-24x13.png 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-36x20.png 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowbefore-48x27.png 48w\" sizes=\"auto, (max-width: 1875px) 100vw, 1875px\" \/><figcaption id=\"caption-attachment-26398\" class=\"wp-caption-text\">Material handlers travel the width of the building, then return empty. Source: Robert Simonis<\/figcaption><\/figure>\n<figure id=\"attachment_26395\" aria-describedby=\"caption-attachment-26395\" style=\"width: 1897px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-26395 size-full\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER.png\" alt=\"Empowered teams focused on optimizing their value stream. Source: Robert Simonis\" width=\"1897\" height=\"1064\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER.png 1897w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-768x431.png 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-1536x862.png 1536w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-375x210.png 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-1024x574.png 1024w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-1280x718.png 1280w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-24x13.png 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-36x20.png 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/productionflowAFTER-48x27.png 48w\" sizes=\"auto, (max-width: 1897px) 100vw, 1897px\" \/><figcaption id=\"caption-attachment-26395\" class=\"wp-caption-text\">Empowered teams focused on optimizing their value stream. Source: Robert Simonis<\/figcaption><\/figure>\n<p>Wherever people or objects cross each other, slowdowns, bottlenecks, and accidents can happen\u2014just like at an intersection. An intersecting production line also creates confusion about which direction to take, resulting in lost time and misplaced materials.<\/p>\n<p><strong>Creating a clear, unobstructed path forward is a key part of optimizing flow<\/strong>.<\/p>\n<h2>Rule No.\u00a03: Make the circle smaller<\/h2>\n<p>Whereas the first two rules of circular manufacturing create a more logical process for operators, the third rule helps cut <a href=\"https:\/\/www.flexpipeinc.com\/us_en\/how-to-deal-with-motion-waste\/\" target=\"_blank\" rel=\"noopener\"><strong>motion waste<\/strong><\/a> and <a href=\"https:\/\/www.leaneast.com\/lean-waste-transportation-motion\" target=\"_blank\" rel=\"noopener\"><strong>transportation waste<\/strong><\/a>.<\/p>\n<p>Imagine the production process as a circle; the larger the circle, the greater the distance employees have to travel from one point to another.<\/p>\n<p>When work cells are placed close together and frequently used tools and parts are within reach, employees will spend less time walking and more time performing the tasks that <a href=\"https:\/\/www.flexpipeinc.com\/us_en\/value-stream-mapping\/\">add value<\/a> to the end product.<\/p>\n<h2>Rule No.\u00a04: The process should be circular, but not circle-shaped<\/h2>\n<p>Once the first three rules of circular manufacturing are implemented, the production line will not be shaped like a circle. Rather, the process will be U-shaped or resemble some variation of this form (for instance, a serpentine or Christmas\u00a0tree pattern).<\/p>\n<figure id=\"attachment_26404\" aria-describedby=\"caption-attachment-26404\" style=\"width: 2101px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-26404 size-full\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart.png\" alt=\"The new process offers a closer option from beginning to end.\" width=\"2101\" height=\"1369\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart.png 2101w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-768x500.png 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-1536x1001.png 1536w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-2048x1334.png 2048w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-375x244.png 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-1024x667.png 1024w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-1280x834.png 1280w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-24x16.png 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-36x23.png 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/U-shaped-flow-process-chart-48x31.png 48w\" sizes=\"auto, (max-width: 2101px) 100vw, 2101px\" \/><figcaption id=\"caption-attachment-26404\" class=\"wp-caption-text\">The new process offers a closer option from beginning to end.<\/figcaption><\/figure>\n<p>Unlike a circle, these shapes create a short distance from one side of the path to the other, reducing total travel time.<\/p>\n<h2>How does circular manufacturing help with line balancing?<\/h2>\n<p>One of the main advantages of a circular configuration over a straight line is that it allows for greater flexibility when it comes to <a href=\"https:\/\/workerbase.com\/post\/how-to-use-line-balancing-in-lean-manufacturing-and-improve-with-digital-tools\" target=\"_blank\" rel=\"noopener\">line balancing<\/a> (levelling the workload across different stations on a production line to prevent bottlenecks).<\/p>\n<p>A straight production line can be balanced only by redistributing tasks to stations to the right or left. But with a circular line, process steps can be redistributed to cells behind as well as to the right or left, providing more options for improving flow.<\/p>\n<p><\/p>\n<div class=\"hs-cta-embed hs-cta-simple-placeholder hs-cta-embed-194948331949\"\n  style=\"max-width:100%; max-height:100%; width:1000px;height:279.1875px\" data-hubspot-wrapper-cta-id=\"194948331949\"><br \/>\n  <a href=\"https:\/\/cta-service-cms2.hubspot.com\/web-interactives\/public\/v1\/track\/redirect?encryptedPayload=AVxigLK%2FXfV8woaValjoHmLTqojmve2JLG5%2BoVBPQpv5r7WOPkKlAwmNeUk2MXWQnrunubsqI5YhVeXCSqTlBU2V27uttlUXXmv60UkwS1rNt50XIFsyL3HhAOMMx5LgHGYcZWWAckxU8tjn7wQu5ej8Jzrq6selxx7OJ9%2B74rtvZ5ijzk6Q482VESU%2BaLQAK8QFSq%2Bt8FyaySORx0Fl&#038;webInteractiveContentId=194948331949&#038;portalId=2641120\" target=\"_blank\" rel=\"noopener\" crossorigin=\"anonymous\"><br \/>\n    <img decoding=\"async\" alt=\"Master the Basics of Lean with 5S Discover how this simple yet powerful method can transform your workspace by reducing waste, improving flow, and building long-term efficiency. &nbsp;\" loading=\"lazy\" src=\"https:\/\/no-cache.hubspot.com\/cta\/default\/2641120\/interactive-194948331949.png\" style=\"height: 100%; width: 100%; object-fit: fill\"\n      onerror=\"this.style.display='none'\" \/><br \/>\n  <\/a>\n<\/div>\n<p><\/p>\n<h2>How does circular manufacturing benefit employees?<\/h2>\n<p>Employees who are accustomed to the <a href=\"https:\/\/www.assemblymag.com\/articles\/94989-lean-layout-dos-and-donts\" target=\"_blank\" rel=\"noopener\">straight-line model<\/a> might be reluctant to try a circular workflow because it appears to be more demanding.<\/p>\n<p>Rather than remaining at one station where they repeat the same task over and over, employees on a circular line switch between different tasks and operate more than one machine.<\/p>\n<p>While this does require operators to learn new skills, the benefits are clear. Moving around and using different muscles is more <a href=\"https:\/\/blog.unex.com\/ergonomics-and-lean\" target=\"_blank\" rel=\"noopener\">ergonomically sound<\/a> than repeating the same motion all day long, so operators tend to experience less fatigue and fewer injuries. Being involved with different stages of production also helps operators feel more engaged with their work.<\/p>\n<p>Looking for evidence of the four rules of circular manufacturing\u2014a workflow that starts and ends close together, does not intersect, reduces travel distances, and is circular but not a circle\u2014is an excellent way to quickly assess whether any manufacturing site is set up efficiently and safely.<\/p>\n<hr \/>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-26382\" src=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG.jpg\" alt=\"\" width=\"814\" height=\"442\" srcset=\"https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG.jpg 814w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG-768x417.jpg 768w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG-375x204.jpg 375w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG-24x13.jpg 24w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG-36x20.jpg 36w, https:\/\/www.flexpipeinc.com\/wp-content\/uploads\/2021\/05\/01-Presentation-Robert_Simonis-ENG-48x26.jpg 48w\" sizes=\"auto, (max-width: 814px) 100vw, 814px\" \/><\/p>\n<p style=\"font-weight: 400;\"><a href=\"https:\/\/www.kceconsulting.com\/home\" target=\"_blank\" rel=\"noopener\">KCE\u00a0Consulting\u00a0LLC<\/a> helps companies around the world improve their manufacturing, logistics, and business operations. Using a learn-by-doing model, <a href=\"https:\/\/www.kceconsulting.com\/home\" target=\"_blank\" rel=\"noopener\">KCE\u2019s consultant<\/a>s train future leaders throughout the supply chain and provide solutions based on Kaizen, Kaikaku, lean process design, operational excellence, and more.<br \/>\nVisit his website: <a href=\"https:\/\/www.kceconsulting.com\/home\" target=\"_blank\" rel=\"noopener\">kceconsulting.com<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Circular manufacturing is a system for maximizing efficiency and reducing waste in a manufacturing site. In this video, Robert Simonis, principal consultant at KCE Consulting, explains the four rules of this lean technique and how they can improve the flow of any work process. \ufeff Rule No.\u00a01: The process should begin and end in the &hellip; <a href=\"https:\/\/www.flexpipeinc.com\/us_en\/circular-manufacturing-the-rules-of-the-circle\/\">Continued<\/a><\/p>\n","protected":false},"author":16,"featured_media":26422,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_eb_attr":"","content-type":"","inline_featured_image":false,"sfsi_plus_gutenberg_text_before_share":"","sfsi_plus_gutenberg_show_text_before_share":"","sfsi_plus_gutenberg_icon_type":"","sfsi_plus_gutenberg_icon_alignemt":"","sfsi_plus_gutenburg_max_per_row":"","_eb_data_table":"","cybocfi_hide_featured_image":"","yasr_overall_rating":0,"yasr_post_is_review":"","yasr_auto_insert_disabled":"","yasr_review_type":"","footnotes":""},"categories":[325],"tags":[],"class_list":["post-26348","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-lean-manufacturing"],"acf":[],"yasr_visitor_votes":{"stars_attributes":{"read_only":false,"span_bottom":false},"number_of_votes":4,"sum_votes":20},"amp_enabled":true,"_links":{"self":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/posts\/26348","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/users\/16"}],"replies":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/comments?post=26348"}],"version-history":[{"count":0,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/posts\/26348\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/media\/26422"}],"wp:attachment":[{"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/media?parent=26348"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/categories?post=26348"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.flexpipeinc.com\/us_en\/wp-json\/wp\/v2\/tags?post=26348"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}