In summary: batch size reduction requires the identification of bottlenecks and their elimination through a systematic set-up reduction programme allowing a decrease in work in progress which reduces the lead time.
* set-up reduction to facilitate batch size reduction;
At the operational level, the identification of set-up reductions to be gained through sequence dependencies can have a great impact on the operational effectiveness of a plant.
5, 10, 20, 40, 80, 160 days supply) for the period order day series, it is possible to make allowances for set-up reductions when items from the same tooling family are scheduled together.
* capacity validation against sequenced schedule taking account of set-up reductions gained through sequence dependencies;
A Pareto analysis is often performed to prioritize set-up reduction in a multimachine production environment.
An example to prioritize set-up reduction procedures
An example of a manufacturing system to prioritize set-up reduction is depicted in Figure 1.
In order to prioritize set-up reduction at machines A, B, C and D using the Pareto analysis, average set-up times (number of set-ups x set-up time) for each machine have to be determined.
Logically, set-up reduction efforts will be targeted first at machine D, then at machine C, followed by machine B and, finally, at machine A.
Regarding the set-up reduction at each machine in this example, there are two noteworthy points.
By focusing set-up reduction, first at machine D, second at machine C, and third at machine B, let us assume that the set-ups at each machine are reduced by 70 per cent.