TOC: Cutting Batch Sizes

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Alex is told that he needs to show an even bigger improvement with the plant. He decides he needs to cut the batch sizes in half on non-bottlenecks. Stacy the inventory control manager is skeptical. The two conflicting parties are Alex and Stacy. (Pages 229-234)

D: Cut batch sizes in half on non-bottlenecks
D': Not cut batch sizes on non-bottlenecks
B: Decrease time to process a batch and to get orders to customers faster
C: Keep efficiencies up
A: Increase sales
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In order to Increase sales I must Decrease time to process a batch and to get orders to customers faster and in order to Decrease time to process a batch and to get orders to customers faster I must Cut batch sizes in half on non-bottlenecks. But, in order to Increase sales I must also Keep efficiencies up and in order to Keep efficiencies up I must Not cut batch sizes on non-bottlenecks. I can't both Cut batch sizes in half on non-bottlenecks and Not cut batch sizes on non-bottlenecks.
RelationAssumption(s)Injection(s)
D-D'1. There is only one batch size

1. They could try it both ways and stick with the way that shows improvement
B-D1. That would make half the work-in-process on the floor

2. Would ease the pressure on cash flow
2. Cash could be tied up in other things besides inventory
C-D'1. Machines will be idle

2. Employees will be idle

3. There will be less set ups
2. Cut back employee hours or enact layoffs
A-B1. Suppliers will increase deliveries

2. We will attract other companies
2. Other companies may be happy with their contracts elsewhere
A-C1. Machines sitting idle are not making money

2. Employees sitting idle are not making money
You would only need half the investment in work-in-process to keep the plant working