Making Flow in Machining and Non-machining Processes with Leveling and Small Lot Sizing: A Kaizen Case Study

This paper presents a kaizen case study that aims to create a smooth flow in both machining and non-machining processes, while addressing the inventory problem that arises in these processes. To accomplish this, we developed a model that analyzes the production requirements of various products in the machining process and the cleaning process of machined parts in the non-machining process. The machining and set-up times for each product differ depending on the CNC machine types used, and set-up labor resources are required whenever a machine switches to produce a different product. Meanwhile, the non-machining process involves cleaning batches of machined parts before they are delivered. In this study, we focus on creating an optimal flow between these two processes by considering different batch sizes and their impact on overall inventory. Our results demonstrate that by implementing a leveling and small lot sizing strategy, we can achieve a more efficient and streamlined production process that reduces inventory levels and improves productivity.