This book describes how the implementation of variable rate launching in
the context of a mixed-model assembly line with unlimited customization
flexibility promotes customer-centric production.
Variable rate launching (VRL) - as opposed to fixed rate launching
(FRL) - eliminates idle time and utility work in mixed-model assembly
lines. Even in the context of limitless customization, which runs the
risk of concentrated peak workloads and possible longer assembly lines,
a variable takt proves to be more economical than a fixed takt. On the
technical side, a fixed takt requires both a healthy balance of process
times and optimal scheduling to create feasible production schedules, as
using average takt does not allow workers enough time to complete their
tasks for more complex products. Because the variable takt relies on
similar process times for a given product across the entire line for one
product, and all products are given exactly the time they need for
assembly, optimal series-sequencing and regular task rescheduling can be
eliminated.
This book is intended as a reference guide for experienced executives in
manufacturing and academics teaching operational effectiveness for
customer-centric production, and makes extensive references to AGCO
Fendt's modern tractor line in Marktoberdorf, Germany. The book also
offers application case studies from companies in related industries
such as automotive, electronics, and machine tools. The book's key
message is that variation should not be universally eliminated from
manufacturing. As such, the book represents a counterpoint to the
philosophy advocated by the Toyota Production System.
