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.
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Boning, M., Breier, H., Berbig, D. (2017). Optimization Model for the Design of Levelling Patterns with Setup and Lot-Sizing Considerations. In: Dörner, K., Ljubic, I., Pflug, G., Tragler, G. (eds) Operations Research Proceedings 2015. Operations Research Proceedings. Springer, Cham. https://doi.org/10.1007/978-3-319-42902-1_54
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DOI: https://doi.org/10.1007/978-3-319-42902-1_54
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