Operations help - QRM / TOC in low-volume / high-mix manufacturing

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August 08, 2019

by a searcher from Northwestern University - Kellogg School of Management in Tampa, FL, USA

Does anyone have experience implementing either quick response manufacturing or theory of constraints in a low-volume / high-mix or make-to-order manufacturing environment?

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Reply by a searcher
from University of Pennsylvania in Chicago, IL, USA
Sounds complicated! In my business manufacturing/operations are everything (need to print/mail millions of official election ballots with very strict time constraints). Would be happy to share ideas/problem solve. There is almost always a solution and it always costs money... better software/better equipment. Question is always is the problem bad enough to justify the expenditure or will the growth pay for the software/equipment investment. If there isn’t a solution that you can buy, then you might have arrived at a huge opportunity to build tremendous value by figuring something out.
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Reply by a searcher
from The University of Chicago in Milwaukee, WI, USA
Hi Daniel, applying basic lean manufacturing principals to a low-volume high mix operation can yield great benefits. I’ve seen it work first hand.

Lead time reduction will reduce the working capital and make the operation more flexible to mix changes. Consider starting with a Value Stream Map to understand your current state. Where does flow stop? What % of your lead time is actually comprised of value-add activities?

Hope this helps. Happy to discuss more if you would like to connect.
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