NDLI: The effect of shop floor continuous improvement programs on the lot size–cycle time relationship in a multi-product single-machine environment

Content Provider	Springer Nature Link
Author	Godinho Filho, Moacir Uzsoy, Reha
Copyright Year	2010
Abstract	While continuous improvement on the shop floor is a major component of many popular management movements such as lean manufacturing and Six Sigma, there are few quantitative studies of the cumulative effects of such improvement programs over time. On the other hand, lot sizing has long been recognized as an important problem in manufacturing management. In this paper, we use a system dynamics model based on the Factory Physics relationships proposed by Hopp and Spearman [1] to examine the effect of different continuous improvement programs on the relationship between lot sizes and cycle times. We compare two different types of improvement programs: large improvements in a single parameter, such as might be obtained by a focused project, or small improvements in many parameters simultaneously. Our results show that the relationship between lot sizes, cycle times, and shop floor parameters is complex and nonlinear. The cycle time benefits of improvements in shop floor parameters are significantly enhanced by the reduced lot sizes they enable; on the other hand, a poor choice of lot sizes can negate the benefits of a continuous improvement program. Although the largest cycle time reduction is achieved by a large reduction in setup time, small, simultaneous improvements in several parameters can achieve much of the same benefit. The cycle time benefits of multiple simultaneous improvements are mutually reinforcing, creating a positive feedback between shop floor improvements and reduced lot sizes. Our model yields insight into why the Toyota Production System has been able to obtain such excellent results over time, and suggests a number of interesting future directions.
Starting Page	669
Ending Page	681
Page Count	13
File Format	PDF
ISSN	02683768
Journal	The International Journal of Advanced Manufacturing Technology
Volume Number	52
Issue Number	5-8
e-ISSN	14333015
Language	English
Publisher	Springer-Verlag
Publisher Date	2010-07-23
Publisher Place	London
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	Lot size Cycle time Continuous improvement System dynamics Factory physics Multi-product single-machine environment Computer-Aided Engineering (CAD, CAE) and Design Mechanical Engineering Production/Logistics Industrial and Production Engineering
Content Type	Text
Resource Type	Article
Subject	Industrial and Manufacturing Engineering Control and Systems Engineering Mechanical Engineering Computer Science Applications Software

Sl.	Authority	Responsibilities	Communication Details
1	Ministry of Education (GoI), Department of Higher Education	Sanctioning Authority	https://www.education.gov.in/ict-initiatives
2	Indian Institute of Technology Kharagpur	Host Institute of the Project: The host institute of the project is responsible for providing infrastructure support and hosting the project	https://www.iitkgp.ac.in
3	National Digital Library of India Office, Indian Institute of Technology Kharagpur	The administrative and infrastructural headquarters of the project	Dr. B. Sutradhar bsutra@ndl.gov.in
4	Project PI / Joint PI	Principal Investigator and Joint Principal Investigators of the project	Dr. B. Sutradhar bsutra@ndl.gov.in Prof. Saswat Chakrabarti will be added soon
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