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One Piece Flow

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Submitted By danrivera
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Manufactura Esbelta

Flujo Continuo

“El producto fluye sin tener demoras por el diseño de las operaciones, registro de ordenes, y la producción sin rechazos, desperdicios, o la necesidad de sobre inventario”
1

Flujo Continuo


El concepto de Flujo continuo aumenta y estabiliza la tasa de flujo del producto



Reduce el Lead Time total
Hace el ciclo de producción más predecible



La meta del LM es que los productos fluyan con la producción en una manera nivelada El flujo de una pieza es el ideal (perfección)



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Flujo Continuo


Maximiza




Minimiza
  

Visibilidad y comunicación Simplicidad Flexibilidad Utilización del operador Seguridad

Movimientos Manejo Esfuerzo

  



3

Flujo Continuo

E

D C

La producción nos conduce de departamentos especializados….

A

B

…a la producción en celdas enfocadas al producto con flujo de una pieza
4

Flujo Continuo
El layout típico de una planta-- ¡¡¡¡ es un verdadero espagueti !!!!

Ensamble

Componentes

Piezas

Proceso
5

Flujo Continuo


Localice el equipo en secuencia apropiada y reduzca al mínimo la separación de la máquina por producto de

familia B Agrupar por la secuencia del proceso para el flujo de una pieza a la vez . C Diseñe un Flujo compartido entre los procesos/equipo.


 A Agrupar

1AA B 2A 3A

C

Prueba 5B 4B

En principio, evite poner operadores en un solo sub-ensamble o lineas de subensambles
Ensamblador

B

1B A 2B

3B

PORQUE ???

“Islas Aisladas”
6

Flujo Continuo
Alternativas del Layout
Flujo de una pieza a la vez transferida manualmente
 Muy eficiente No muy flexible Flujo en línea recta (multi-procesos)

1

2

3

4

1

2

3

4

Caminar

Organice las piezas, herramientas y los materiales que se necesiten en el punto de uso.

Desperdico
7

.

Flujo Continuo
Las líneas U pueden ofrecer ventajas
10 9 8 7
Entrenamiento cruzado requerido

6

El trabajo se mueve en sentido contrario a las manecillas del reloj

5 1 2 3 4
Los operadores dentro de la celda, el material de primeras entradas primeras salidas (PEPS) está afuera de la celda y al alcanze.
8

PORQUE??
 

(La mano de obra, que es predominantemente derecha, se acercará al siguiente paso de trabajo con la mano dominante. )
Reduzca al mínimo el espacio y distancia recorrida Mayor flexibilidad, 25 - el 30% más eficientes

.

Flujo Continuo

9

Flujo Continuo

10

Flujo Continuo


Producir al ritmo de la demanda (Takt Time)
 

Producir solamente la demanda actual (cliente “Pull”) No sobre producir solo por mantener la máquina ocupada



Balancear operaciones en la celda usando el Trabajo Estándar Producir y mover el material en pequeños lotes




Use la reducción del Set up para manejar lotes pequeños.



Reducir el volúmen, tiempo de producción y el inventario. Aumenta la productividad, calidad y flexibilidad





Flujo de una pieza a la vez es lo ideal
11

Flujo Continuo

Departamento de manufactura

Inventario

Departamento de manufactura

Inventario

Empaque

Inventario

Almacén

Distribución

Flujo tradicional del lote
Inventario

Operador

Operador

Empaque

Distribución

 Menos Inventario  Menos productos defectuosos a reparar

Fujo de una pieza  Menos espacio requerido  Mejor capacidad en balanceo de línea  Lead Time más corto
12

 Rápido tiempo de respuesta

Flujo Continuo
“Monumentos” presenta desafíos únicos
Antes de la mejora, todas las celdas de ensamble alimentan una sola operación

Después de la mejora, los procesos de ensamble fluyen en unidades más pequeñas

Utilice “tamaño correcto” del equipo
13

Flujo Continuo
“Monumentos”
Flujo de una pieza Salida Entrada

Flujo de una pieza

Controla a través de Kanban gradualmente se reduce el tamaño de “buffer”

Inventario total máximo de 120 en esta localización

Surtimiento por lotes

Proceso por lotes
Requere un lote de 120)

14

Flujo Continuo


La suavización de la producción es el proceso de estabilizar la producción de acuerdo a la demanda de cliente la cual es variable.
LA META: Mantener un plan de producción diario que proporcione a la operación de manufactura un flujo uniforme de productos, secuencialmente programados en base a los pedidos actuales del cliente
Demanda del cliente Promedio de Demanda Diaria Calidad Tiempo



Nivelar la producción es un requerimiento básico para optimizar la implementación de la manufactura esbelta 15

Modelos Mixtos


La secuencia de los modelos mixtos “suaviza” la demanda de los productos a traves del horizonte de planeación Demanda mensual 1200 2400 2400 Demanda diaria 40 80 80

Modelo Pequeño Mediano Lujoso

Una secuencia de L-M-P-M-L repetido 40 veces por día mantiene una mezcla apropiada de los modelos.
16

Lead Time
5-Días a la semana. 20-Días al mes
Producto #1 Demanda del cliente = 200/Mes Producto #2 Demanda del cliente = 200/Mes Producto #4 Demanda del cliente = 500/Mes Demanda total del mes : 1000 unidades 10 Dias Producto #3 Demanda del cliente = 100/Mes2-Semanas +1-Dia 10 Dias

¿Cuanto tiempo toma llenar un pedido del cliente para cada unidad? Ahora . . .

Secuencia mensual: 1 x 200 (Cambio) 2 x 200 (Cambio) 3 x 100 (Cambio) 4 x 500 Suavizamiento del Proceso: Producto #1 200/20 = 10 por dia

Como podemos reducir dia Lead time ? el 4-Hours ¿Cuanto tiempo Producto #2 200/20 = 10 por toma llenar un Producto #3 100/20 = 5 por dia pedido del cliente Producto #4 500/20 = 25 por dia para cada Total por dia = 50 unidad?
..
4-Hours + 10 Minutes
4-Hours

Una secuencia diaria posible 4-1-4-2-4-1-4-2-4-3 (Repetir 5 veces)

17

Resumen del Flujo Continuo


Visualiza la planta como estaciones de una línea de ensamble




Arregla el proceso para que fluya
Traslapa / liga operaciones para eliminar el manejo de material y el WIP.



Usa la programación nivelada y la producción de modelos mixtos para que el flujo sea “suave”
Programa debajo de la capacidad permite planear, resolver problemas y dar mantenimiento. Se esfuerza para usar el flujo de una pieza a la vez. Utiliza el sistema “Pull”
18



 

FIN
19

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