A convex relationship between batch size production, WIP and manufacturing management philosophies: A study using the Factory Physics methodology approach

Marcelo Carneiro Gonçalves, Izamara Cristina Palheta Dias, Raimundo José Borges de Sampaio


The study presents a quantity model that use a Factory Physics methodology approach (HOPP; SPEARMAN, 2001). It aims study the impacts of five continual improvement projects (variability in the process and on arrival, time to failure and repair, and set up time), also it simulates the model to three production batch sizes in the middle level of work in process (WIP) and Utilization. In addition, the application in the use in a production environment with a single machine that processes multiple products. The results of work is possible get insights and subsidies with the model that support a number of modern tools and manufacturing management philosophies, Six Sigma; SMED (Single Minute Exchange of Die), Toyota Production System / Lean Manufacturing and Quick Response Manufacturing (QRM). Besides, the model also serves to assist in the choice of different possibilities for continual improvement programs on the factory floor.


Factory Physics; production batch size; continual improvement; WIP; Utilization


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