Lean in High-Mix, Low-Volume: How Bespoke Machine Makes It Work
Lean manufacturing is often associated with high-volume, repetitive production. But what about environments where every order is different? Where batch sizes are small, and changeovers are constant?
That’s the reality of High-Mix, Low-Volume (HMLV) manufacturing, and it’s where lean thinking is needed most.
At Position Automation, we design bespoke machine solutions that bring lean efficiency to even the most variable production environments.
The HMLV Challenge
HMLV operations face unique obstacles:
- Frequent changeovers
- Complex scheduling
- High setup time
- Risk of overproduction or underutilisation
- Difficulty standardising processes
But with the right tools and mindset, lean can thrive in this environment.
How Position Automation Enables Lean in HMLV
Our bespoke machine systems are built for flexibility, speed, and precision, making them ideal for lean HMLV operations. Here’s how:
- Quick Changeovers (SMED): Modular tooling and programmable operations reduce setup time between product types.
- Pre-Loaded Programs: Operators can switch between part recipes with a single command.
- One-Piece Flow: Machines are designed to process individual units efficiently, no batching required.
- Real-Time Data: Live performance metrics help teams adjust quickly and make informed decisions.
- Lights-Out Capability: Run small batches overnight without operator supervision.
Real-World Example: Lean in a Custom Fabrication Shop
A custom metal fabricator needed to process dozens of unique profiles per week, each with different hole patterns and cut angles. Manual setups were eating into production time.
With Position Automation’s bespoke machine system:
- Setup time dropped from 25 minutes to under 5
- Operators could load new programs instantly
- One-piece flow replaced batching
- Lead times shrank, and customer responsiveness improved
Lean wasn’t just possible, it became their competitive edge.
Lean + HMLV = Strategic Agility
When lean principles meet flexible automation, HMLV manufacturers gain:
- Faster response to customer demand
- Lower inventory and WIP
- Higher machine utilisation
- More consistent quality
- Empowered teams who can adapt and improve
At Position Automation, we help you build systems that flex with your product mix, without compromising on speed or quality.
Ready to Lean into Complexity?
High mix doesn’t have to mean high waste. With Position Automation, you can bring lean discipline to even the most dynamic production environments.
Discover how we optimise production at www.position-automation.co.uk or contact us at sales@position-automation.co.uk
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