Product wheels to achieve mix flexibility in process industries

Abstract

Purpose – Mix flexibility is a critical manufacturing flexibility type needed to produce a company's range of products. Oftentimes, multiple products are produced on shared resources which require coordination mechanisms to ensure their effective utilization. This paper aims to explore the applicability of the product wheel concept as a coordination mechanism that can be used to manage shared resources in operational mix flexibility achievement in process industries. Design/methodology/approach – The product wheel concept is a construct from the theory of lean manufacturing adoption in process industries. This construct is applied as a sequencing coordination mechanism, where similar products are grouped together to run consecutively in a production schedule. A single case study is used to illustrate the development and evaluation of a product wheel design. Findings – The results show that the product wheel concept does achieve the aim of grouping similar products in the production schedule, and, as such, can be used to improve the production planning process through the reduction of the number of time-intensive changeovers without sacrificing product availability to meet customer demand. The product wheel, however, is not a mathematical optimization technique; but is instead a heuristic technique which requires the use of judgment and experience to achieve an optimal design. Originality/value – A theoretical contribution to the study of mix flexibility has been made, where the application of the product wheel construct presents a novel approach to the study of operational mix flexibility achievement, via the sequencing of products on shared manufacturing resources.