Algorithm for an IT-based scheduling of flow line production in a one of a kind manufacturing

A one of a kind production usually requires a high manual operating effort to finish every part on time. High lead times, great stocks before the work units and very uncertain predictable completion dates are also typical. Therefore, the author started to transfer the flow line concept from the batch production to the one of a kind production in cooperation with several companies. After two years of research a solution was found and three companies began to implement the flow line concept for a one of a kind manufacturing in their daily business. After some minor adjustments the concept today meets the expected results: Lead times and stocks reduce up to 50% and the efforts of operating and progress control minimize. Completion dates can be reliably calculated even before manufacturing starts due to the fixed lead time of a flow line. On the other hand, the effort needed for scheduling the manufacturing is dramatically higher. Therefore, the author developed a mathematical algorithm which allows an IT-based scheduling of the flow line production in a one of the kind manufacturing. This paper will present the concept of the specific flow line production as well as the new developed IT-based scheduling algorithm.