Demand impact on batch size
For a fixed batch time calculation we do not consider the demand difference between each references.
In the real life, if a reference A has, for example, 6 times more demand than the reference B, we have the chance to see on the launcher 6 batches of A following each others. It means that the set-up operator is going to "save" at least 5 change-overs and consequently he/she will not use totally the allocated time for changeovers.
If we want to use it fully, we can divide by 3 the batch size of the 2 references without increasing the total allocated time for changeovers. As consequences, the loop (the inventory) is going to reduce by 3 for the 2 references!
Of course, the example chosen is simple because we took only 2 references. For a more complex situation, our Kanban sizing tool can help you to use this situation to reduce the total inventory required by the system.
On the right an explanation is given about how our tool is optimizing the batch sizes based on the demand.
If we want to respect the % of DOT allocated for changeovers, batch sizes are also function of consumption mix.
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