This study aims to address the challenges faced by healthcare manufacturing SMEs in high-mix, high-volume environments, particularly in light of the COVID-19 pandemic.The authors propose the implementation of the Production Wheel framework as a solution to optimize operational efficiency and cost-effectiveness. Using real-world anonymized data from a high-mix, high-volume manufacturing project, the authors evaluate the feasibility and impact of this framework. The findings indicate significant reductions in changeover and inventory costs, with notable improvements in production efficiency. The study highlights the potential of the Production Wheel in healthcare manufacturing while providing insights based on authentic industry data.
The Production Wheel framework is introduced as an 8-step method that encompasses analyzing historical volumes, identifying key product families, developing current and future state value stream maps, assessing capacity utilization and implementing Kanban-based pull systems with supermarkets between processes. This approach is grounded in Lean manufacturing principles and is tailored to the specific needs of the healthcare manufacturing industry.
The adoption of the Production Wheel framework enables healthcare manufacturers to align their production more closely with actual demand, minimizing waste and reducing overheads. This agile approach facilitates the adaptation to a high mix of products without compromising efficiency, ensuring a resilient and responsive supply chain that can effectively meet the evolving needs of the market.
While this conceptual paper introduces the Production Wheel framework in the context of healthcare manufacturing, future research should focus on the practical implementation and empirical validation of the proposed approach. Case studies and quantitative analyses of the framework’s impact on operational efficiency, inventory management and cost-effectiveness would provide valuable insights for academics and practitioners.
The Production Wheel framework offers a practical approach for healthcare manufacturers to navigate the challenges posed by the COVID-19 pandemic and the increasing demand for customized products. By integrating this methodology alongside flexible manufacturing systems, manufacturers can enhance their ability to adapt to market disruptions while maintaining optimal operational performance.
This paper contributes to the Lean Manufacturing literature by introducing the Production Wheel concept as a novel framework for healthcare manufacturing. The proposed approach addresses the unique challenges faced by the healthcare manufacturing sector in the wake of the COVID-19 pandemic and provides a strategic roadmap for optimizing operational efficiency and cost-effectiveness.
