Postprint version. Published in CIRP Annals - Manufacturing Technology, Volume 63, Issue 1, April 29, 2014, pages 389-392.
NOTE: At the time of publication, the author Ahmed Deif was not yet affiliated with Cal Poly.
The definitive version is available at https://doi.org/10.1016/j.cirp.2014.03.108.
A dynamic systems approach is proposed to investigate challenges of implementing production leveling and associated costs. A model of a lean cell is developed using system dynamics. The model captures various lean tools influencing production leveling. Comparative cost analysis between various leveling implementation policies for stochastic demand with multiple products is conducted. Results showed that determining the most feasible leveling policy is highly dictated by both capacity scalability cost and limitations. The developed model and revealed insights can help lean practitioners to better decide on when and how to implement production leveling as well as determine production lots sizes.