A Lot-sizing Model for Just-in-time Manufacturing

We consider the problem of determining lot sizes of multiple items that are manufactured by a single capacitated facility. The manufacturing facility may represent a bottleneck processing activity on the shop floor or a storeroom that provides components to the shop floor. Items flow from the facility to a downstream facility, where they are assembled according to a specified mix. Just-in-time (JIT) manufacturing requires a balanced flow of items, in the proper mix, between successive facilities. Our model determines lot sizes of the various items based on available capacity and four attributes of each item: demand rate, holding cost, set-up time and processing time. Holding costs for each item accrue until the appropriate mix of items is available for shipment downstream. We develop a lot-sizing heuristic that minimizes total holding cost per time unit over all items, subject to capacity availability and the required mix of items.