explain using inventory to smooth production
Batch and queue production Produces uneven flow to compensate, for this international solution is to add inventory buffers this is not ideal because inventory is a waste.
Explain levelling production with uniform schedules
A better solution than inventory buffers is to use uniform production schedules, which are based on demand. The daily production schedule can be made consistent so that scheduling is easier and parts flow smoothly without adding inventory.
What are the requirements for level production schedules?
Continuous stable demand (demand can be managed to minimize variation by segregating customers and products with uniform demand, often the majority of products and sales volume are in this category)
Short set up times (this is necessary for small batch production)
Production equals demand (The level schedule should be based on actual demand, and the updated periodically to reflect a change in demand)
What should be the primary focus of levelling production?
The first focus should be on levelling the production of the highest value products often only a few of many products account for over half of sales. These are the ones to focus on.
Explain the master production schedule
Production plan: Use for planning capacity to make forecasted demand contains aggregate production plans at a high-level time horizon is months or years.
Master production schedule: Specifies plan production of each item product during eighth period of time time horizon is a few weeks. 
Explain the difference in schedule from traditional batch manufacturing to lean production
And traditional batch manufacturing the production schedule differs for every. Whereas in lean production, the schedule is made so that every period is the same.
Explain level scheduling and pull production
Pull production requires a schedule for only the last stage of production so if the schedule is uniform, overall flow will be smooth
Explain levelling production for mixed model production
When products require assembly, the production schedule is known as the final assembly schedule. FAS.
Are the batch size requirements for balancing mixed model production
- Takt time for each product workstation satisfies the required product takt time
- The sequence assignment for each product is as efficient as possible
What are the three production philosophies?
Made to stock (MTS)
Assemble to order (ATO)
Make to order (MTO)
Explain make to stock production
Make products in anticipation of demand
Relies on push production
Small variety of end products
Schedule end products
Does not require customer order first
Advantages: short lead times, repetitive manufacturing for batches of similar goods
Disadvantages: requires accurate product forecasting, when demand is different from supply products end up in inventory or sold at a loss
Explain assemble to order production
Subassemblies are made according to forecast then combined into unique combinations requested by clients
Pull production paradigm
Large number of end parts assembled from small number of models
Fewer subprocess than MTO
Advantages: reduce inventory, orders can be customized, quick delivery
Disadvantages: lack of inventory that is ready to deliver, longer waiting times than MTS, management of subassembly inventory
Explain make to order production
Unique products made from standard materials and parts
Higher unit cost
Pull production requiring customer order first
Companies carry very little on hand inventory
Advantages: mass customization, very little waste
Disadvantages: longer lead times, increased manufacturing complexity, higher product cost
Explain backward scheduling
Uses kown information concerning manufacturing processed to generate production scheduled given a desired delivery date. Used for ATO and MTO production
What is forward scheduling
Fulfilling orders as soon as possible with the materials on hand, manufacturing is performed at capacity with no allowance for additional orders. New orders are added to the queue as soon as they are processed.
When is a planning bill used
When the number of possible final parts is large
Explain the different in BOM for MTS vs ATO
MTS: number of unique BOMs is equal to the number of available option combinations (multiplication)
ATO: number of BOMs is equal to the number of options (addition)
How can scheduling problems be minimized
Simplify the BOM
Use group technology and standard parts/models
Make only what is needed
Produce in small lot sized that are easy to count
Use simple visual control systems
Do not overload the shop
Use short lead times
What are the advantages of level scheduling
Batch production becomes more repetitive
Low inventories
Flexible and responsive
Simple to control
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Unit 8 - Level Scheduling19
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Unit 8 - Synchronizing And Balancing Processes13
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Unit 8 - Quality Of Design30
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Unit 9 - Planning And Control In Pull Procution13
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Unit 9 - Managing The Supply Chain12
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Unit 9 - Six Sigma5
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Unit 9 - SPC23
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Unit 1 - History And Background7
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Unit 2 - Lean Fundamentls10
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Unit 3 - Waste Elimination21
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Unit 4 - TQM Customer Focused Quality5
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Unit 4 - Small Lot Produciton10
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Unit 5 - Setup Time Reduction13
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Unit 5 - Focused Factories6
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Unit 5 - Manitaining And Improving Equipment6
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Unit 6 - Pull Prodiction6
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Unit 7 - Standard Operations8
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Unit 7 - Workcells7
