TO SCHEDULING AND
(manufacture to EOQ) encouraged
large lots (volume) to
runs do lower direct
cost but often have an adverse reaction
service, smooth manufacturing load, and
(See Figuro I.)
to level load manufacturing without lot sizing had varied
results. Labor utilization clearly
results. But customer service and inventory
did not show
mixed-model scheduling approach provided a breakthrough in
thinking. Make a little of everything,
The plant now could be level loaded, with lots
produced providing good customer service,
inventory was kept to a minimum. (Sce"Eigttnr3.)
order for pure mixed-model scheduling
to work setup times and ordering
costs must be dramatically
reduced. Costs will rise and nonproductive
machine capacity will be
APPROACH TO ADVANCED
Certainly, most companies must optimize inventory
investment manufacturing efficiency and customerservice.
However, reducing setup costs and order costs are formidable
challenges to most companies. Setup reduction
can take years implementing. Using advanced approaches
to business rules and ABC analysis, many companies can implement
a modified approach to selecting
an ideal factory model for scheduling.
There are well-defined steps to integrating your companies
thought ware and software. Significant time must be
spent organizing for such an effort. The steps listed below
will need to be modified for different types of manufacturing
technologies. We will discuss a modified approach
to establishing a mixed-model scheduling process:
Prepare ABC analysis.
Combine like items (product family—customer
Identify business rules for customer service levels.
Develop inventory and shop floor philosophy.
Communicate with supply chain.
Develop setup matrix.
Develop order launch rules (priority planning).
Develop manufacturing loading strategies.
Certain products to certain lines
Standard setup tools for "A" items
Load leveling/final assembly scheduling rules
Develop customer allocation
Load software order modifiers.
Document all rules.
Manage all exception messages.
Post implementation review (quarterly).
Let's discuss some of these items in more detail.