Lean principles are difficult to employ in complex environments, but materials requirement planning has well-known limitations. The theory of constraints, which is complementary to lean manufacturing when it comes to low volumes and complex environments, may provide an answer.
roa lean methodology
with their large batch approach and resulting long lead times and bloated inventory levels. Large lot sizes are a way of compensating for the fixed cost of a process, such as changeover or set-up costs, transaction-level costs (e.g., releasing orders, issuing parts, closing and reconciling orders, moving product batches into stocks, etc.), and other per order factors. With a large run, these costs can be distributed over a larger number of units, and thus become a smaller cost on a per piece basis. As