007_ 多品种小批量轮番生产计划模型(英文)

企业实践案例（英文资料）：

“多品种-小批量轮番生产”

均衡化生产计划与排程模型

Production

Customer

Fluctuation in lot size

1

Leveling method: Leveling the quantity per

model and consistency of the model order.

•Leveling the quantity and production sequence takes place at the manufacturing resource.

• A preferably fine leveling simulates a ‘perfect’customer who picks up regularly in small portions.

•Leveling supports the Continuous Improvement Process implying a reduction in lot size and therefore in replenishment lead time.

•Shortened replenishment lead times yield in increased flexibility (easy and fast adjustment to unanticipated disruptions such as changes in

customer demand).

•Through a consistent customer demand, stock can be held on a minimum from the preliminary processes to the suppliers.

2

2

Parameters for leveling

•Distinction into high and low runner:

–Models with high frequent and constant demand (high runner)

–Models with low frequent and/or uneven demand (low runner)•Customer tact or demand quantity/frequency per model •Capacity (offered by production ):

–Personnel (Shift model)

–MAE (OEE, change over time)

•Leveling period and withdrawal sequence

•Lot-size

•Planning period:

–replanning frequency of the leveling board

•Availability (parts quality, organizational interruptions, OEE)

3

Case study: Production program

based on change over optimization -units allocation Product Current Current EPEI ?recorded number

demand / month demand / day fluctuations Change over/day ?

A5,600280+/-10 %

B5,600280+/-50 %

C5,600280+/-50 %

D4,800240+/-20 %

E4,000200+/-25 %

F3,200160+/-20 %

G3,200160+/-15 %

H2,400120+/-10 %

a48024?

b48024?

c32016?

d32016?

e1608?

f804?

g804?

h804?

i804?

j804?

k804?

l402?

m402?

n402?

o402?

23 TTNr.36.800 pcs1840 pcs

4

Example:

How often should we produce different part numbers ? Introduction EPEI = Every Part Every Interval

Current situation:

23 part numbers *)

customer demand 1840 pcs / day

2 shifts, 8 hrs/shift

2 x 10 min breaks per shift

cycle time = 27 sec / pc

change over time = 10 min

availability = 95 %

max productivity

packaging/delivery volume 40 pcs

*) overview part number and volume distribution see data sheet

2 shifts = 960 min

breaks = 40 min

remaining time for change overs48 min

872 min

availability 95%

828 min

customer demand / day x cycle time

1840 x 27 = 828 min

time in min.

Time stack

Takt Time = 920 min x 60 sec / 1840 pcs = 30 sec / pc 920 min

max number of change overs = 4