Achieving Balanced Workload Distribution Amongst Cross-Trained Teams

Abstract

This research is focused on improving the flow of items through the cross-trained teams of a leather furniture manufacturing company, which manufactures a high mix of products. Presently, a Push control strategy is applied to control production, but this causes uneven build-up of items for processing (i.e. workload) at the cross-trained teams. Hence, this research investigates the application of the CONstant Work In Process (CONWIP) strategy to control Work in Progress (WIP) and at the same time ensure balanced workload distribution amongst the teams. It uses the release signal from downstream to monitor the work rate of individual teams and regulate the release of new items for them to process. Results of simulation experiments conducted on the system show that the application of CONWIP, particularly with consideration of the cross-trained teams in its item release decisions, ensures a balanced distribution of workload amongst the teams. This eradicates the constant need for human intervention to redistribute items between the cross-trained teams, which is a current challenge for the case study company.