Batch Size 1

Today, we are experiencing a batch size transformation. Although the result is not always batch size 1, production is changing from traditional mass production to smaller product batches and even one-off production.

Customers' desire for increasingly customized and configured products is growing. Accordingly, the batch size 1 production strategy is becoming increasingly important in companies - with the aim of meeting these individual customer requirements.

In principle, you can always specify a batch size when you manufacture. Even with mass production of 1,000,000 units. Of course, nobody does that, so let's take another quick look at what differentiates the batch size.

This involves the production of very large quantities at low cost.

Series production is the little sister of mass production. Here, too, large quantities are produced, but they are limited to a certain number. After that, the series is complete.

This is where mass production and individualization meet. Personalized products are produced cost-effectively as part of mass production. This requires modular product design and flexible production.

The aim here is to achieve the quantity at which the unit costs (e.g. for warehousing, set-up times and material orders) are lowest. The whole thing can even be calculated, e.g. using Andler's batch size formula.

In order to be able to respond to individual customer requirements, companies must first and foremost offer a high level of flexibility. Batch size 1 requires the use of modern technologies and processes that make such flexibility possible. These technologies and processes can include

• the use of modern production and information technologies such as ERP, MES, PLM, IIoT, AI or even product configurators for customers

• the automation of processes, e.g. automatic material provision via AGVs or AGVs

• Processes such as rapid prototyping and 3D printing

Batch size 1 must not only be affordable for the customer, but also for the manufacturing company.

In order to be able to react flexibly to all customer requirements, an increased stock level is often necessary to cover the most diverse eventualities.

The frequent changeover from one product to the next results in increasing set-up costs and set-up times.

The production process itself also becomes significantly more complex and creates new dependencies and conditions.

As a result, production planning must be optimized to avoid longer throughput times. Quite apart from the fact that the flexibility of batch size 1 makes long-term planning more difficult.

Batch size 1 also has advantages and, as you might have guessed, these are geared towards the customer. At the end of the day, the customer decides whether to buy from you or not. If they want a customized product and you can't help them with this, they will go to the competition.

Of course, it is entirely up to you and your business model whether you want to offer batch size 1. However, individual production promotes your customer orientation to a considerable extent and can also ensure significantly higher customer satisfaction.

The automotive industry is a prime example of batch size 1. You have probably used a vehicle manufacturer's configurator before. From the seats to the audio system to the color and rims, you can put together your individual vehicle, which is then built according to your wishes.

Batch size 1 is also not a rare guest in mechanical engineering. Do you need a machine for the three-sided machining of shift sleeves for car gearboxes or a separator for small, contiguous parts? Then you will find what you are looking for in special machine construction, which will manufacture the machine you need individually for you.

Batch size 1 puts the customer at the center of your production. The aim is therefore to fulfill the individual wishes of your customers. Although this means a number of challenges for your company, customized production increases your competitiveness in the long term.