High Mix Low Volume Lean Fact Sheet

Lean manufacturing has struggled when there are:

• Hundreds or even thousands of product variants produced in the same product line

• Many unique paths through all of the operations

• Cycle times and changeover times vary greatly by product

• Processes that must be sequenced to resolve capacity limitations

• Short product life cycles with continual engineering change

• Demand patterns with spikes and dips

• Configured products with unique bills of materials and routings

• Make-to-order fulfillment with short lead times

mcaConnect’s Strategic Services group supports lean transformation with methodology, tools, and experience gained from working in these challenging environments. Our target market of high mix low volume manufacturers has forced us to adapt and extend lean principles to support:

• Takt time in highly branched value streams

• Every part every interval (EPEI) to accommodate changeovers between products

• EPEI when every part is not ordered every interval

• Value stream mapping for HMLV

• Supermarket sizing based on interval

• Sequencing and flow

• Buffer strategies to level demand

• Shared resources across value streams

• Management of data integrity for HMLV

• Fixed interval scheduling

• Long-term planning vs. short-term scheduling

About mcaConnect

Established in 2002, mcaConnect has grown into one of the largest US-based Microsoft Gold Certified Partners focused exclusively on delivering Microsoft Dynamics AX and CRM solutions and services to mid-market and enterprise-size manufacturing, energy, and distribution companies.  Headquartered in Denver, CO, mcaConnect has offices throughout the world to support multi-national implementations.

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