Optimizing Batch Sizes
Optimizing Batch Sizes
(OP)
I am working on multiple projects within my cell to reduce WIP inventroy, lead time, increase productivity etc. Im sure all you manufacturing engineers are constantly doing the same thing. Let me preface by saying my degree is Mechanical engineering and I have limited manufacturing experience.
In any event, I would like to examine the possibility of changing our batch sizes to optimize efficiency/performance. We have a great product mix (means change over) as well as inconsistent batch sizes between parts. In any event, I am looking for a model or some advice on batch size optimization. Can anyone point me in the right direction?
In any event, I would like to examine the possibility of changing our batch sizes to optimize efficiency/performance. We have a great product mix (means change over) as well as inconsistent batch sizes between parts. In any event, I am looking for a model or some advice on batch size optimization. Can anyone point me in the right direction?





RE: Optimizing Batch Sizes
[ That of course neglects the cost of providing more machinery than he could use at once, because it was already there. It also neglects the pennies on the dollar that an aggressive accountant would recoup by selling off the surplus machines, or the astronomical cost of buying them back from the tool dealer should the company recover. ]
Similarly it's possible to set up CNC machines with flexible tooling or idle stations on large beds to also get zero setup time and an economical batch size of one.
Beyond that, you can invest in fast-change tooling, e.g. robotic die changers for large stamping presses, to reduce the setup time to just a few minutes ... if you have the budget for the automation.
You can probably drive yourself crazy reading books about this stuff, but major changes require major money and major backing from management, both factors that are often lacking.
In the meantime, it might be productive to break down the processes as they are now, beat on them in a spreadsheet, and look for ways to make incremental improvements. That exercise may eventually reveal the actual bottlenecks where it would actually be productive to spend money.
Mike Halloran
Pembroke Pines, FL, USA
RE: Optimizing Batch Sizes
I used Discrete Simulation software to do quickie analyses to model manufacturing operations and determine bottlenecks, batch sizes, evaluate alternative production line layouts, etc. Years ago I was so successful with that method that I published a paper on it and it was well received. You can download it here www.bl
The last I looked, there was a inexpensive and powerful little simulator package www.simul8.com that may serve your purposes well.
TygerDawg
RE: Optimizing Batch Sizes
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Software For Metalworking
http://mrainey.freeservers.com
RE: Optimizing Batch Sizes
http://www.goldratt.com/
You can also find it in regular bookstores. There may be a few things in there you will find of interest in terms of dealing with process improvement, bottlenecks, and subsequent effects.
Regards,