El flujo de una sola pieza (One-Piece Flow, OPF) es un principio ampliamente promovido en la manufactura lean, frecuentemente ilustrado con diagramas animados que muestran cómo mover una sola unidad a través del proceso es más rápido y eficiente que mover lotes. Sin embargo, en la práctica, son pocos los entornos manufactureros donde este modelo encaja de forma realista.
¿Por qué no se aplica más ampliamente el OPF? Porque la mayoría de los procesos no se parecen a las ilustraciones ideales. En industrias como alimentos, bebidas, moda artesanal o fermentación, el tamaño del lote está condicionado por el propio proceso o por economía de escala. Incluso en procesos discretos o por lotes, las distancias físicas, los tiempos de espera o la necesidad de operaciones en batch hacen que mover una sola unidad no sea viable.
Entonces, ¿qué deberíamos buscar?
Más que imponer un flujo de una sola pieza, el verdadero objetivo lean es alcanzar un “flujo fluido y constante”. Un flujo que, aunque se trabaje por lotes, sea:
Predecible
Sin interrupciones
Sin desperdicio innecesario
Capaz de cumplir fechas y calidad para el cliente
En la mayoría de los casos, lo que rompe el flujo no es el tamaño del lote, sino la variación del proceso: fallas en equipos, falta de materiales, tiempos de espera o reprocesos. Así que, reducir la variación es mucho más poderoso que reducir el tamaño del lote.
Caso práctico: óptica y lentes
Ron Jacques, con más de 35 años en manufactura lean, relata cómo una planta de lentes oftálmicas mejoró sus indicadores mediante six sigma. Primero redujeron la variabilidad, lo que permitió acortar tiradas, optimizar inventarios y mejorar el cumplimiento. Es decir, el proceso se volvió más estable, lo que hizo viable operar con lotes más pequeños.
En otras palabras, reducir el tamaño del lote puede ser una consecuencia deseable, pero no el objetivo inicial. De hecho, eliminar los amortiguadores (como el inventario excesivo) puede obligar a resolver problemas de raíz y mejorar el sistema en su totalidad.
Los usuarios del software de Bentley pueden presentar sus proyectos en el programa de los Premios Year in Infrastructure, independientemente de la fase en la que se encuentre el proyecto.
Las cadenas de suministro involucran piezas móviles complejas y dinámicas. Para mantenerse competitivo, debes crear un sistema flexible que pueda adaptarse a las interrupciones, aprovechar
Expo Cesvi 2018, como cada año, convocará a todos los participantes en la industria de la reparación automotriz, en especial la reparación por colisión.
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