The logic of lead time reduction is dependent on, as we have seen, a decrease in lot size. However, this entails a multiplication in the number of manufacturing orders, and therefore in the number of dispatch lists. To avoid bringing stores to a standstill, we will work by backflushing with decentralized stocks of components in the workshop (floors stocks). This technique of backflushing will be especially applied to the second-level options of the MPS because the final order assembly multiplies especially order finishing. In our example, Fig. 5 describes planning bills after reduction of lead times.
This was possible because improvements made in the assembly workshop (operative times, transit times and global delays) lead the firm to realize the whole assembly of the flowmeter components corresponding to a customer order, in the same (1 week) that the old organization needs with assembly tubes and electronic assembly (see Figs. 4 and 6).