Production Levelling

Sequence and schedule the factory for maximum performance

To quote Taichi Ohno, considered by most to be the founding father of Lean production:

On a production line, fluctuations in product flow increase waste. This is because the equipment, workers, inventory, and other elements required for production must always be prepared for peak production.

A search for production levelling on the internet will point to a production levelling technique used in the assembly industry, known as Heijunka. This approach is inadequate for the process industry although the underlying concepts are still valid.

A suitable product levelling approach for the process industry has only just been developed by Dupont. This method of production levelling for the process industry is known as Product Wheel design. Product Wheels are a structured way of;

  1. increasing usable capacity,
  2. reducing standby labour costs,
  3. reducing inventories, and
  4. improving customer delivery performance

We can help facilitate the search for your best Product Wheel for any of your processing lines. Product wheels offer a number of benefits;

  1. Delivers the best economic balance between total inventory cost and changeover cost
  2. Incorporates the perspectives of production, planning and supply chain experts in your organisation
  3. Identifies the optimum sequence for your unique product portfolio
  4. Defines the best cycle time for each SKU
  5. Provides a fact-based foundation for determining inventory requirements
  6. Defines the level production schedules that connect production with the heartbeat of demand
  7. Delivers more stable production schedules so that unexpected events can be accommodated with less stress
  8. Creates more reliable windows for maintenance and engineering