What are the disadvantages of one-piece flow?

Answer 1

One-piece flow can lead to increased setup times, as each individual item may need to be adjusted or configured separately, which can disrupt production continuity. Additionally, it may not be suitable for all types of products, particularly those with high variability or low demand, making it less efficient in certain contexts. Implementing one-piece flow can also require significant changes to existing processes and training for workers, which can involve upfront costs and time. Finally, it may expose the production line to greater risks, as a single failure can halt the entire process.