I have visited several factories that have successfully implemented one-piece flow. On the other hand, I have also visited unsuccessful factories that have attempted to implement one-piece flow but have not been able to achieve it. Two months ago, I wrote an article that covered one missing element in many of the unsuccessful attempts, standardized work.
Another key element to achieving one-piece flow is achieving basic stability. In fact, this is a prerequisite to achieving true one-piece flow.
Highly capable processes. Processes must be able to consistently produce good product. If there are many quality issues, one-piece flow is impossible.
Highly repeatable processes. Process times must be repeatable as well. If there is much variation, one-piece flow is impossible.
Equipment with very high (near 100%) uptime. Equipment must always be available to run. If equipment within a manufacturing cell is plagued with downtime, one-piece flow will be impossible.
The above three elements are critical to one-piece flow success; together, those three elements define the term "basic stability." If basic stability is in place, one-piece flow is possible (and not very difficult to achieve).
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