Adjusting the production sequence is a popular way of handling production lines with a product-dependent workload. This post is part of rather long series on Mixed Model Sequencing. In the last post I discussed the basics of sequencing and the calculation of the takt time. This post describes the basics of adjusting workload and buffering – but still for a simple case of only one imbalanced station. Subsequent posts will get more serious with multiple imbalances. But let’s continue with our simple single imbalance example. Continue reading Mixed Model Sequencing – Basic Example Workload and Buffering
Mixed Model Sequencing – Basic Example Introduction
Your products may have different work content on your production line, which may make your line less efficient. One possible solution is Mixed Model Sequencing, a way to adjust the sequencing of your products to make the average work content stable. In previous posts I looked at the basics, at how to avoid the problem in the first place and how to play with capacity. However, especially for large complex lines (i.e., automotive), sequencing is often a suitable approach to manage different work contents. Continue reading Mixed Model Sequencing – Basic Example Introduction
Mixed Model Sequencing – Adjust Capacity
Production lines with a product mix may have different workloads at different stations for different products. This can cause waste. In this third post in the series I will look at options on how to adjust the available capacity to ease this problem. In my next post I will look at Mixed Model Sequencing to adjust workload differences. Continue reading Mixed Model Sequencing – Adjust Capacity
Mixed Model Sequencing – Just Make the Problem Go Away
Your production line may have different workloads for different product variants. This unevenness causes waste and overburden. In this series of posts I will look at ways to address this unevenness. The first post was an introduction to the topic. This second post will look at ways to simply eliminate the problem – although this may not be feasible for many cases. In the next posts I will look at adjusting the capacity and finally at adjusting the product sequence through Mixed Model Sequencing. Continue reading Mixed Model Sequencing – Just Make the Problem Go Away
Mixed Model Sequencing – Introduction
In a mixed model production line, different products may have different work content at different stations. Hence, some stations may need a longer or shorter time depending on the product. This requires careful planning of the assembly line. If this is not taken into account, it may cause significant idle time with all stations along the line. This is the first of a (very) long series of posts looking at Mixed Model Sequencing (i.e., the behavior of unbalanced workloads, and different ways to address these issues). Continue reading Mixed Model Sequencing – Introduction
On Adjusting Supervisor Workload
In my last post I looked at the span of control. This is very related to the workload of the supervisor. Hence in this post I would like to discuss how to adjust the supervisor workload. Usually, this is to reduce the workload, as most shop-floor supervisors are in my opinion overworked and have no time left for improvement. In some cases, however, you may have a situation where you want to give the rare underworked supervisor more work. Most of the approaches presented will work in both directions. Let’s look at some ideas: Continue reading On Adjusting Supervisor Workload
On the Span of Control
Pretty much all companies are based on a hierarchical structure. One superior manages multiple subordinates. The question is: How many subordinates should be managed by a superior? This is also called the span of control. This depends on a number of factors. Let’s have a look at efficient group sizing. Continue reading On the Span of Control
Diseconomies of Scale
The economy of scale is well known. The larger a company gets, the more efficient it becomes. However, this trend does not go on indefinitely, and eventually turns into a diseconomy of scale. In this post I will look at the diseconomies of scale, and also the very related Parkinson’s Law. Continue reading Diseconomies of Scale