Track: Production Planning and Management

Abstract

Despite research demonstrating the operational benefits of lowering the number of product offerings, manufacturing companies commonly service markets where customers require a wide range of products with various feature options at unpredictable intervals. While lean manufacturing principles have been recognized as enablers of operational excellence in high-volume manufacturing operations, doubts remain concerning the concepts' application in high-mix, low-volume, make-to-order contexts. This project investigates the applicability of Toyota Production Systems within this manufacturing environment. To be competitive, the company must produce high-quality, low-cost goods that fulfil customer standards with short lead times. Using a qualitative research design with a case study analogy and implementing waste elimination, mistake proofing and pull methods, a production cell increased the percentage of sales delivered on time to the customer by 15%.