Dynamic modelling of impact of lean policies on production levelling feasibility

A dynamic systems approach is proposed to investigate challenges of implementing production leve and associated costs. A model of a lean cell is developed using system dynamics. The model capt various lean tools influencing production levelling. Comparative cost analysis between various leve implementation policies for stochastic demand with multiple products is conducted. Results showed determining the most feasible levelling policy is highly dictated by both capacity scalability cost limitations. The developed model and revealed insights can help lean practitioners to better decid when and how to implement production levelling as well as determine production lots sizes. ling del and and case study [4] demonstrated the need to balance between Heijunka and the just in sequence approach if the customer requirements are dynamic in nature. A dynamic capacity mechanism to better manage the trade-off between Heijunka and responsiveness was developed as a rate y of * Corresponding author. is adopted and modified to incorporate production level mechanisms as well as their associated lean costs. The new mo is shown in Fig. 1. The displayed system is composed of a dem component that captures the stochastic nature of the demand translates it to takt time and pull rate. Production is modelled lean cell with three stations. Production is controlled by a pull which is function of takt time and is affected by availabilit mat whi capa (JIT) lean are c