Haessig, Tio (2025) Implementing Lean Manufacturing in a High-Mix Low-Volume Environment with Sequence-dependent Changeover and Alternative Routing. Masters thesis, Concordia University.
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Abstract
This thesis explores the development of a Lean manufacturing system at company ABC that operates in a tailored to a high-mix, low-volume manufacturing environment characterized by sequence-dependent changeovers and alternative routing. To achieve this, a methodical approach was followed to identify the key sources of waste and their root causes, which is demonstrated through the system's current value stream map. Because of the variability in cycle times at the batch processes, sequence-dependent changeover times, and alternative routings in Assembly processes, it’s challenging to create pull sequence at the pacemaker with generic lean guidelines. In order to address these challenges, a new scheduling method, "concurrent scheduling," has been developed. The method consists of controlling the pacemaker through a schedule while simultaneously coordinating the downstream batch process with a product wheel, and introducing a sequential pull system between the two processes. The schedules and the product wheels are offset by a delay to enable the pacemaker to supply the batch process efficiently. The batch process is the pivotal point of the value stream to determine the lowest possible production interval, also known as Every-Product-Every-Interval (EPEI), and the optimization model also aims to minimize the EPEI. Once the pacemaker scheduling and EPEI is determined, the quantities of the finished goods supermarket and the necessary work-in-progress of the First-In-First-Out lanes have been determined to achieve a lean flow. The study results have been summarized into a future state map, providing the company with a framework to improve its production system.
The results indicate significant improvements, including a 58.2% reduction in total production lead time, total control and predictability over inventory levels, a standardized value stream and management, improved production flexibility, and greater expected customer satisfaction. While the individual solutions and the methodology's application can assist manufacturers facing similar problems in achieving operational excellence, this thesis provides insights into the overall application of Lean in High-mix, Low-volume environments.
| Divisions: | Concordia University > Gina Cody School of Engineering and Computer Science > Mechanical, Industrial and Aerospace Engineering |
|---|---|
| Item Type: | Thesis (Masters) |
| Authors: | Haessig, Tio |
| Institution: | Concordia University |
| Degree Name: | M.A. Sc. |
| Program: | Industrial Engineering |
| Date: | April 2025 |
| Thesis Supervisor(s): | Kuzgunkaya, Onur and Demirli, Kudret |
| Keywords: | Lean, High-mix low-volume, Alternative routing, sequence-dependent changeovers, Value Stream Mapping |
| ID Code: | 996220 |
| Deposited By: | Tio Haessig |
| Deposited On: | 04 Nov 2025 16:40 |
| Last Modified: | 04 Nov 2025 16:40 |
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