Lot sizing and changeover optimization have become prominent in today’s increasingly disruptive supply chain world. Effective coordination of these two interconnected concepts is crucial for achieving lean manufacturing and turning manufacturers into adaptive agile entities. The primary goal of lot sizing is to find the right balance between economies of scale and minimizing holding costs. Minimizing changeover time is essential to increase production flexibility, reduce downtime, and enhance overall efficiency. Manufacturers must balance lot sizes and changeover optimization to align with the production strategy, market demands, resource availability, and organizational capabilities. It becomes a balancing exercise of efficiency and effectiveness. 

Established strategies such as economic production quantity (EPQ), quick changeovers (SMED), and just-in-time (JIT) yield lean manufacturing in this context but no longer render a company with a relevant competitive edge. Organizations that embrace the concept of adaptive agility achieve lean operations and build supply chain resilience and overall resilience of the manufacturing ecosystem. Advanced planning systems (APS) and effective data analytics enable manufacturers to transition to adaptive agile entities. Demand sensing and forecasting (DSF) become more robust and dynamic based on real-time data and market conditions. Additionally, increased forecast accuracy boosts analyst and shareholder confidence in financial reporting.

roi-X offers extensive expertise and experience in this space for both Fortune companies and SMEs, nationally and internationally. roi-X has repeatedly instituted accurate forecasting, restructured supply, and pivoted demand-supply management at adaptive, agile sensing and fulfillment. Quarterly forecast accuracies of 98%+, on-time-in-full deliveries at 95%+, and inventory turns >12/year have been routinely established. Working capital and costs have been sustainably diminished by at least 20% while garnering customer approval rates of 95%+. roi-X is also accustomed to compensating for out-of-region losses via arbitrage optimization. Leverage roi-X’s core expertise in transformational Execution Excelllence to become agile and resilient.