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Scheduling Issue

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Viewing 11 posts - 1 through 11 (of 11 total)
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  • #54012

    Nizar SAIDANE
    Participant

    Hello all,
    I need a guide for a Lean scheduling system for a manufacturing process with low batch sizes, high variety of products, constrained capacity, changeover and fluctuated demand.

    Many thanks,
    Best Regards,

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    #192906

    Mike Carnell
    Participant

    @nizar2012 Is this a redundant question or am i having a flashback?

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    #192919

    Nizar SAIDANE
    Participant

    @Mike-Carnell: This is a question.
    I am searching a scheduling method for a manufacturing process with low batch sizes and hgh variety of products.

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    #192930

    Chris Seider
    Participant

    SMED is your partial answer, OEE analysis for losses associated with set ups, and smart scheduling.

    Some product change overs will take more time than others–especially for processes that use pipes to convey raw materials or finished goods. For example, it takes less time to change from lightly colored product to a darker product. As someone said in the past…it’s much easier to see chocolate in the vanilla then vanilla in the chocolate. It’s obviously best to optimize product sequence to minimize time lost for set ups.

    There are more techniques others will advocate but you need to do the above first.

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    #192931

    MBBinWI
    Participant

    @nizar2012 – Nizar: Too little info to make any truly useful suggestions. As my friend Chris says, you need to reduce set-ups as much as possible, commonize raw materials and components to the maximum extent, and keep variability as late in the process as possible. I once worked on a product that had different capacity construction equipment. The design had a standard wheelbase, but required higher structural strength. We accomodated this by making the thickness increase go inside, thus keeping the weld fixtures common. We included fingers and tabs cut in the piece parts so as to ensure that the wrong piece parts couldn’t be put together, but the overall weld fixture was common. No changeover and poke-yoked so that you ensured the right pieces went together.

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    #192932

    MBBinWI
    Participant

    @cseider – Chocolate and vanilla product, that’s just a hypothetical theory, right?

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    #192936

    Chris Seider
    Participant

    @MBBinWI I love cinnamon and peanut butter or cinnamon and chocolate frozen yogurt best. :)
    http://yumi-licious.com/

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    #192946

    Nizar SAIDANE
    Participant

    @cseider, @Mike-Carnell:
    Thanks for your answers.
    We are producing clamps for aerospace industries. It starts with the cutting press.
    Changeover Time varies from 15 to 45 minutes, depending on the material to be used (Alu/stainless steel) and some other parameters.
    We have around 1500 different items, and expected to raise to 2600 in few months.
    Batch sizes are non regular and varies from 100 to 5000/item.
    The required Lead Time is 10 days from order receipt to delivery.
    I have a problem scheduling this process, with much more items and less quantities/batch.
    I am keen to have general ideas about scheduling methods, or any example that seems appropriate to our process.

    Many thanks in advance,

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    #192949

    MBBinWI
    Participant

    @nizar2012 – Any chance that you have repeatable minimum quantities on some recurring basis? If so, and let’s assume it’s on a monthly basis, you could set up a repetitive schedule for the first 3 weeks that had exactly the same schedule and put all the variability in the last week. Yes, it makes the one week hell, but it’s only the one week with the others being more stable and repeatable, instead of all weeks hell. Just a thought.

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    #192992

    Nizar SAIDANE
    Participant

    @Mike-Carnell: thanks for your answer.
    NO CHANCE unfortunately to get min repeatable quantities. No forecast. Maximum visibility is about 3 weeks.
    The planning orders is scheduled within the week. No Monthly planning is used.
    its a hell matter!

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    #192993

    Ravi Prakash B
    Participant

    What is the total Percentage capacity utilization.

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