The product wheel (PW) design process has practical methods for finding the optimum sequence, therefore minimizing changeover costs and freeing up useful capacity. This book describes this proven technique for dealing with all of the issues related to multiple product situations. It walks the reader through a logical, detailed, step-by-step process for designing and implementing the PW technique. Breaking down a fairly complex design process down into discrete, practical, manageable steps, it includes a case study from actual practice that illustrates the design process and the benefits.

Introduction: Why Product Wheels? Process Industry Challenges; Product Wheel Basics; The Problem: Production Sequencing, Campaign Sizing, Production Leveling; The Solution-Product Wheels; The Product Wheel Design and Implementation Process; Step 1: Begin with an Up-to-Date, Reasonably Accurate VSM; Step 2: Decide Where to Use Wheels to Schedule Production; Step 3: Analyze Products for a Make-to-Order Strategy; Step 4: Determine the Optimum Sequence; Step 5: Analyze the Factors Influencing Overall Wheel Time; Step 6: Put It All Together-Determine Overall Wheel Time and Wheel Frequency for Each Product; Step 7: Arranging Products-Balancing the Wheel; Step 8: Plotting the Wheel Cycles; Step 9: Calculate Inventory Requirements; Step 10: Review with Stakeholders; Step 11: Assign Responsibility for Allocating PIT Time; Step 12: Revise the Scheduling Process; Step 13: Develop an Implementation Plan; Step 14: Develop a Contingency Plan; Step 15: Get All Inventories in Balance; Step 16: Confirm Wheel Performance-Put an Auditing Process in Place; Step 17: Put a Plan in Place to Rebalance the Wheel Periodically; Case Studies and Examples