{"id":722,"date":"2024-05-31T15:50:25","date_gmt":"2024-05-31T15:50:25","guid":{"rendered":"https:\/\/controldepiso.com\/?p=722"},"modified":"2026-10-16T23:07:50","modified_gmt":"2026-10-16T23:07:50","slug":"lorem-ipsum-dolor-sit-amet-consectetur-quisque-dolor-4","status":"publish","type":"post","link":"https:\/\/controldepiso.com\/en\/lorem-ipsum-dolor-sit-amet-consectetur-quisque-dolor-4\/","title":{"rendered":"4 Logistics Problems in Factories and How to Solve Them"},"content":{"rendered":"<div data-elementor-type=\"wp-post\" data-elementor-id=\"722\" class=\"elementor elementor-722\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-197ea25c e-flex e-con-boxed e-con e-parent\" data-id=\"197ea25c\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-5c180be0 elementor-widget elementor-widget-text-editor\" data-id=\"5c180be0\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\n<p class=\"wp-block-paragraph\">We have been fortunate to work with several of the largest companies in Colombia during these 10 years, such as Tecnoqu\u00edmicas, Colombina, Harinera del Valle and Carvajal among others, accompanying them in an improvement process that continues today.<\/p>\n\n<p class=\"wp-block-paragraph\">During this time we have evidenced situations that slowed down production at some point and that, thanks to the analysis of accurate data, have become opportunities for improvement that have increased manufacturing capacity between 12% \u2013 14% each year<em>a 12% improvement in a company that produces 10,000 million a year, translates into an increase of 1,200 million in production<\/em>).<\/p>\n\n<p class=\"wp-block-paragraph\">Doing an analysis of the reason that most causes a loss of productivity, we find that\u00a0<strong><span style=\"color: #252839;\">\"Failures in Internal Logistics\"<\/span><\/strong>is the one that is most repeated. It is presented in 73% of the 31 companies examined. Its main reasons are:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Delay in en listments<\/li>\n\n<li>Lack of planning<\/li>\n\n<li>Poor quality of raw material<\/li>\n\n<li>Lack of raw materials<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">As several of these companies had not started the automatic capture process, these reasons were hidden until software was implemented where the real impact of these stops could be evidenced and strategies were implemented that allowed the growth we mentioned above. Below we will explain what these failures consist of and how to fix them.<\/p>\n\n<ol class=\"wp-block-list\">\n<li>\n<h5><strong><span style=\"color: #252839;\">Delay in set-ups:<\/span><\/strong><\/h5>\nFailures during the set-up process happen when the necessary elements to start production are missing or are not arranged in the optimal way and generate delays.<\/li>\n<\/ol>\n\n<p class=\"wp-block-paragraph\"><strong><span style=\"color: #252839;\">Solution:<\/span><\/strong>\u00a0Dividir los alistamientos por tipos, ya que algunos productos necesitan m\u00e1s tiempo y operaciones que otros (unos necesitan cambio completo de materia prima y otros solo cambio de presentaci\u00f3n) Luego de identificarlos y codificarlos adecuadamente, el siguiente paso es hacer un Pareto de Paradas, donde se encontrar\u00e1 que el 20% de los motivos son los que ocasionan el 80% de los retrasos d\u00e1ndole visibilidad a cu\u00e1les son los problemas que m\u00e1s resultados le dar\u00e1n si son solucionados. <span style=\"color: #252839;\"><strong>(<a style=\"color: #252839;\" href=\"https:\/\/controldepiso.com\/en\/38-pareto-de-paradas\/\">See how to get a Pareto stops<\/a>).<\/strong><\/span><\/p>\n\n<p class=\"wp-block-paragraph\">Para que estas mejoras sean efectivas, debe utilizar una herramienta de captura autom\u00e1tica de informaci\u00f3n que brinde un dato exacto sobre el tiempo invertido en el alistamiento, ya que si se llevan reportes manuales, los operarios introducir\u00e1n siempre los mismos (e incorrectos) valores. <strong><span style=\"color: #252839;\">(<a style=\"color: #252839;\" href=\"https:\/\/controldepiso.com\/en\/45-optimizacion-de-captura-de-datos\/\">(See an example in: When to automate data capture?<\/a>)<\/span><\/strong><\/p>\n\n<ol class=\"wp-block-list\" start=\"2\">\n<li>\n<h5><span style=\"color: #252839;\"><strong>Lack of planning when producing:<\/strong><\/span><\/h5>\nThis happens when there is little communication between the sales team and the plant team or when there is no planning that aligns with sales objectives. This can cause shortages or oversupplies that generate waste due to expiration (in the case of food companies) and take up more space than necessary in warehouses. Some situations that alter planning are impossible to avoid, such as lack of raw materials, order priorities (urgent and last-minute), behavior of external markets or unavoidable unforeseen events.<\/li>\n<\/ol>\n\n<p class=\"wp-block-paragraph\"><span style=\"color: #252839;\"><strong>Solution:<\/strong><\/span>\u00a0Conformar un equipo de planeaci\u00f3n integradas por distintas \u00e1reas y disciplinas que pueda consultar en tiempo real los estados de producci\u00f3n, que tome decisiones basadas en informaci\u00f3n exacta y puedan responder en tiempo real y reprogramar lo necesario para no generar insatisfacci\u00f3n de clientes o perder negocios importantes. Este es uno de los pasos m\u00e1s importantes para alcanzar una Producci\u00f3n de Clase Mundial. <strong><span style=\"color: #252839;\">(<a style=\"color: #252839;\" href=\"https:\/\/controldepiso.com\/en\/55-6-pasos-para-alcanzar-la-excelencia-operacional\/\">(See the 6 steps to operational excellence<\/a>).<\/span><\/strong><\/p>\n\n<ol class=\"wp-block-list\" start=\"3\">\n<li>\n<h5><span style=\"color: #252839;\"><strong>Poor quality of raw material:<\/strong><\/span><\/h5>\nIt can be observed when the raw material generates waste and it is necessary to slow down to keep it as little as possible (causing slow production). The problems that this generate are: The machine needs more setup time at start-up, it takes longer to produce the first good unit generating start-up waste, raw material is wasted and causes the machine to have to work at a lower than optimal speed, micro stops are generated due to raw material adjustments, damage to it or unnecessary replacements.<\/li>\n<\/ol>\n\n<p class=\"wp-block-paragraph\"><span style=\"color: #252839;\"><strong>Solution:<\/strong><\/span>\u00a0First, the lost time and waste that is being generated by the poor quality raw material, lost time such as machine adjustments, raw material changes, bursting or misalignment of material, among others, must be measured. Product waste must be classified by quantities and concepts, to identify if they correspond to poor quality of raw material, they must be classified in the 5 most common cases (poorly packaged product, dirt, porosity, cracks, appearance, etc.). This information must be collected accurately and in real time, to prevent the problem from spreading throughout the shift or subsequent shifts. Once this information is used, a prioritization is made and measures can be taken to solve them. As a result of this information, these two aspects can be looked at:<\/p>\n\n<p class=\"wp-block-paragraph\"><strong><span style=\"color: #252839;\">A.<\/span><\/strong> Cuando hay una cantidad muy grande de peque\u00f1as paradas (menores a 4 minutos), es supremamente importante tener captura autom\u00e1tica, pues es muy dif\u00edcil llevar un control manual de estos tiempos tan peque\u00f1os. Un ejemplo de estas peque\u00f1as paradas son que la materia prima se revienta, el material de empaque hace que el producto se derrame. En estos casos hay que ajustar la m\u00e1quina y acomodar el producto para continuar la producci\u00f3n. En algunas de las empresas estudiadas fue exitoso hacer un piloto con otro proveedor de materia prima con mejores condiciones de calidad y evaluar si las paradas que cre\u00edmos eran causadas por su calidad, disminuyen en tiempo y frecuencia (y si el costo justifica el cambio). En otros procesos lo que econ\u00f3micamente tuvo \u00e9xito fue modificar la m\u00e1quina y hacer que haga un trato m\u00e1s suave a la materia prima y el producto, sin sacrificar la velocidad del proceso, y as\u00ed usar la misma materia prima e inclusive usar materiales m\u00e1s econ\u00f3micos con esta mejora en la m\u00e1quina. <strong><span style=\"color: #252839;\">(<a style=\"color: #252839;\" href=\"https:\/\/controldepiso.com\/en\/56-nuestra-experiencia-con-las-6-grandes-perdidas-en-la-industria-colombiana\/\">(Read our experience with the 6 big losses, see the section \"Quality\" in the Colombian industry.<\/a>)<\/span><\/strong><\/p>\n\n<p class=\"wp-block-paragraph\"><strong><span style=\"color: #252839;\">B.<\/span><\/strong> En el caso donde se prioriza el desperdicio por tipo y por pesos, debe hacer un Pareto donde se identifique cu\u00e1l es el 80% de la problem\u00e1tica del desperdicio (ejemplo: suciedad en el producto), luego debe reunirse con el equipo de trabajo e identificar la causa ra\u00edz del problema, para encontrar qu\u00e9 mejorar. Es importante verificar que no sean problemas internos de almacenamiento o transporte. Al final se resume en hacer pilotos con otros proveedores y modificaciones al proceso y ver si realmente hay un impacto y as\u00ed propagar la soluci\u00f3n en toda la planta.<\/p>\n\n<ol class=\"wp-block-list\" start=\"4\">\n<li>\n<h5><span style=\"color: #252839;\"><strong>Lack of raw material:<\/strong><\/span><\/h5>\nThis error is repeated so many times that it becomes part of the landscape, the operator arrives at the machine and has no material with which to start production, causing delays and non-compliance in scheduling. The most recurrent reasons for this to happen are: Inventory errors, lack of material planning, lack of planning by the purchasing department and that the material is not prepared.<\/li>\n<\/ol>\n\n<p class=\"wp-block-paragraph\"><span style=\"color: #252839;\"><strong>Solution:<\/strong><\/span>\u00a0When these stoppages have been measured and are considered to generate a significant loss of time, we recommend the following actions: Make periodic inventories depending on the frequency of this error, Prepare raw materials separately for each planned production order, implement warehouse readiness procedures, schedule to have raw materials ready before stopping the machine.<\/p>\n\n<p class=\"wp-block-paragraph\">\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2014\u2013<\/p>\n\n<p class=\"wp-block-paragraph\">The proposed solutions can be implemented manually and will generate a visible impact on your production, however, the adoption of an automatic information capture system will allow more accurate results to be obtained, in less time and using fewer personnel resources, but the real value of these systems is that you can follow up on the proposed solutions,  evaluate the impact they have had and make adjustments to them in real time.<\/p>\n<p>\u00a0<\/p>\n<p><a href=\"https:\/\/controldepiso.com\/en\/productos\/\"><img fetchpriority=\"high\" decoding=\"async\" class=\"aligncenter wp-image-1608 size-large\" src=\"https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-1024x183.png\" alt=\"\" width=\"800\" height=\"143\" srcset=\"https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-1024x183.png 1024w, https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-300x53.png 300w, https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-768x137.png 768w, https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-1536x274.png 1536w, https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-2048x365.png 2048w, https:\/\/controldepiso.com\/wp-content\/uploads\/2026\/10\/link-productos-18x3.png 18w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/><\/a><\/p>\n<p><\/p>\n<p class=\"wp-block-paragraph\"><strong><span style=\"color: #daa520;\"><span style=\"font-size: 20px;\"><span style=\"color: #252839;\">If you want to receive articles like this by email, sign up!<\/span> <span style=\"color: #19d76e;\"><a style=\"color: #19d76e;\" href=\"https:\/\/controldepiso.com\/en\/blog-subscription\/\" target=\"_blank\" rel=\"noopener\">Click Here.<\/a> <\/span><\/span><\/span><\/strong><\/p>\n<p><span style=\"color: #daa520;\"><strong><span style=\"font-size: 20px;\"><span style=\"color: #252839;\">Lo invitamos a ver nuestros casos de \u00e9xito:<\/span> <span style=\"color: #19d76e;\"><a style=\"color: #19d76e;\" href=\"https:\/\/controldepiso.com\/en\/casos-de-exito\/\" target=\"_blank\" rel=\"noopener\">Click Here!<\/a><\/span><\/span><\/strong><\/span><\/p>\n<p><span style=\"color: #daa520;\"><strong><span style=\"font-size: 20px;\"><span style=\"color: #252839;\">Lo invitamos a ver el video de c\u00f3mo funciona nuestra plataforma OPTTIME:\u00a0<span style=\"color: #19d76e;\"><a style=\"color: #19d76e;\" href=\"https:\/\/youtu.be\/Rk4L8lCbZVk\" target=\"_blank\" rel=\"noopener\">Click Here!<\/a><\/span><\/span><\/span><\/strong><\/span><\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>","protected":false},"excerpt":{"rendered":"<p>Hemos tenido la fortuna de trabajar con varias de las empresas m\u00e1s grandes de Colombia durante estos 10 a\u00f1os, como Tecnoqu\u00edmicas, Colombina, Harinera del Valle y Carvajal entre otras, acompa\u00f1\u00e1ndolas en un proceso de mejoramiento que contin\u00faa actualmente. Durante este tiempo hemos evidenciado situaciones que frenaban en alg\u00fan punto la producci\u00f3n y que, gracias al [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":723,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"page_builder":"","footnotes":""},"categories":[1],"tags":[],"class_list":["post-722","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/posts\/722","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/comments?post=722"}],"version-history":[{"count":5,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/posts\/722\/revisions"}],"predecessor-version":[{"id":1718,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/posts\/722\/revisions\/1718"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/media\/723"}],"wp:attachment":[{"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/media?parent=722"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/categories?post=722"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/controldepiso.com\/en\/wp-json\/wp\/v2\/tags?post=722"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}