Optimization Model for the Design of Levelling Patterns with Setup and Lot-Sizing Considerations

Mirco Boning (), Heiko Breier () and Dominik Berbig ()
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Mirco Boning: Karlsruhe Institute of Technology (KIT)
Heiko Breier: Karlsruhe Institute of Technology (KIT)
Dominik Berbig: Robert Bosch GmbH

A chapter in Operations Research Proceedings 2015, 2017, pp 401-407 from Springer

Abstract: Abstract Production levelling (Heijunka) is one of the key elements of the Toyota Production System and decouples customer demand from production orders. For the decoupling period a levelling pattern has to be designed. Existing approaches for the design of levelling patterns are majorly limited to large-scale production. Therefore, this article proposes a novel optimization model regarding the requirements of lot-size production. Relevant, sequence-dependent changeovers are considered. An integer, combined lot-sizing and scheduling model is formulated. The four target criteria changeover times, smoothness of daily workload, variance of lot-sizes and similarity of production sequences are aggregated into one optimization model. In a real case study of an existing production plan a clear improvement of changeover times, similarity and smoothness of workloads is realized.

Keywords: Production Plan; Vehicle Route Problem; Customer Order; Changeover Time; Bullwhip Effect (search for similar items in EconPapers)
Date: 2017
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Persistent link: https://EconPapers.repec.org/RePEc:spr:oprchp:978-3-319-42902-1_54

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DOI: 10.1007/978-3-319-42902-1_54

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