Lean Production Control at a High-Variety, Low-Volume Parts Manufacturer

Eaton Electric General Supplies, a parts manufacturing unit that supplies parts for Eaton's electrical business unit, implemented several lean control elements in its high-variety, low-volume production units. These control elements include a constant work-in-process mechanism to limit and control the amount of work in process, first-in-first-out sequencing to control the order of departing jobs, and takt time to control the timing of departing jobs. We conducted a simulation study to (1) illustrate the control-element operations for planners and supervisors, (2) indicate the general applicability of the elements, and (3) support the development of a production progress screen to support the workers in the production units.