Lean Thinking: Better Living Through Setup Reduction

E. N. Weiss, R. Goldberg, John Leschke
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Abstract

This note reviews the effect setup time, batch size, and throughput time have on each other by providing everyday examples. Excerpt UVA-OM-1501 Jul. 29, 2013 LEAN THINKING: BETTER LIVING THROUGH SETUP REDUCTION Lean transformation typically involves the reduction or elimination of inventory. In a given system, inventory can function as a hedge against demand variability, quality variability, or equipment malfunction. Inventory can also take the form of batches of work in progress. The smaller the batch, the more flexible and responsive a business can be. The “ideal” batch size is a single unit, but in practice, such batching tends toward prohibitive setup costs and insufficient output capacity. So the size of an optimal batch is inversely proportional to the cost and duration of its required setup. For almost 100 years, the economic order quantity (EOQ) formula has been used to calculate a given batch's tradeoff between holding and setup costs. But in the 1940s, Taiichi Ohno, founder of the Toyota Production System, realized that reducing setup times by changing the system achieved better results than optimizing a system that may be inherently inefficient. As setup costs decline, so does EOQ; that is, if the goal is to reduce rather than optimize inventory, setup reduction can be viewed as an investment. To understand setup reduction, one must understand the interaction of setup time, batch size, and value delivery. . . .
精益思维:通过减少设置来改善生活
本文通过提供日常示例,回顾了设置时间、批处理大小和吞吐量时间对彼此的影响。精益思维:通过减少设置改善生活精益转型通常涉及减少或消除库存。在给定的系统中,库存可以作为对需求变化、质量变化或设备故障的对冲。库存也可以采用批量工作进行的形式。批量越小,企业就越灵活,反应也越快。“理想的”批量大小是单个单元,但在实践中,这样的批量处理往往会导致高昂的设置成本和不足的产出能力。因此,最优批的大小与所需设置的成本和持续时间成反比。近100年来,经济订货量(EOQ)公式一直用于计算给定批次的持有成本和设置成本之间的权衡。但在20世纪40年代,丰田生产系统(Toyota Production System)的创始人大野耐一(Taiichi Ohno)意识到,通过改变系统来减少安装时间,比优化一个本来可能效率低下的系统取得了更好的效果。随着安装成本的下降,EOQ也在下降;也就是说,如果目标是减少而不是优化库存,那么减少设备设置可以被视为一种投资。要理解设置减少,必须理解设置时间、批大小和价值交付. . . .之间的相互作用
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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