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Heijunka, Planning and Scheduling, Sequencing Activities, Mixed Model
Published in Protzman Charles, Whiton Fred, Protzman Dan, Implementing Lean, 2018
Protzman Charles, Whiton Fred, Protzman Dan
In “build to order systems,” the products are not made until an order is received. Most companies use some type of enterprise resource planning system. Within that system is a master schedule and an MRP, or some type of shop floor control system. These systems consolidate requirements, order materials, and then release scheduled orders based on lead-time offsets. “Lead-time offsets” are the lead times put into the system for the supplier, receipt, inspection, manufacture, etc. This creates what we call a “push-type system.” In this system, MRP (based on the planner’s review and approval) is the “trigger” for the order. The work orders are released and then scheduled in the various work centers in the shop.
Cost Categories
Published in David M. Anderson, Design for Manufacturability, 2020
Factory finished goods inventory can be eliminated by building products to order, instead of building to forecast and then holding products in a warehouse until ordered by distributors or customers. Like WIP inventory, finished goods inventory may cost the same to carry, except that finished goods are completed and therefore are more valuable. Using 25% of value per year, $10 million worth of finished goods in inventory would cost $2.5 million per year to carry. Build-to-order can eliminate factory finished goods inventory and, thus, save its yearly inventory carrying cost.
BASICS Model: Check (C)
Published in Protzman Charles, Protzman Dan, Keen William, The BASICS Lean™ Implementation Model, 2019
Protzman Charles, Protzman Dan, Keen William
In build-to-order systems the products are not made until an order is received. Most companies use some type of enterprise resource planning system. Within that system is a master schedule and an MRP or some type of shop-floor control system. These systems consolidate requirements, order materials, and release scheduled orders based on lead-time offsets.
The future of manufacturing systems engineering
Published in International Journal of Production Research, 2018
A factory has several objectives. Like aerospace systems, some objectives are targets that must be met closely, some are concerned with stability, and others involve the minimisation of cost. Target objectives for a factory include:Meeting demand. Build-to-stock products should be available to customers whenever they want them. Build-to-order products should have short production lead times and manufacturers should be able to make early and reliable delivery promises.Meeting product specifications. That is, it must manufacture with high quality.Stability-related objectives include:Robustness and insensitivity to disruptions. As much as possible, supply failures, machine failures and worker absence should not prevent a manufacturer from meetings its targets. Inventory and spare capacity are physical means that allow the system to absorb disruptions.Flexibility and reconfigurability. The factory should react effectively to such disruptions as engineering changes and demand changes.Cost minimisation objectives include:Limited inventory.High capacity utilisation.The challenge for factory designers and operators is that the cost objectives conflict with the target and stability objectives. Minimising inventory and maximising capacity utilisation make it harder to reliably meet demand and to provide robustness. To design and operate manufacturing systems that deliver the best possible performance economically, we must develop and use scientific tools for understanding variability, uncertainty and randomness.