Lot Size 1 explained simply
Imagine that every product is manufactured individually and only to order – really just a single piece per job. That is exactly what Lot Size 1 means: you do not produce in large series, but instead each product is made specifically to the customer’s requirements. It sounds expensive – but it is not, as long as production, planning and logistics are digitally networked and automated. This makes individual manufacturing economically viable.
Background information
The term Lot Size 1, also known as Mass Customisation, describes the production paradigm in which individual items are manufactured under industrial conditions – with efficiency close to that of series production. It enables maximally customised products, for example in mechanical engineering or the automotive industry, where vehicles can be fully configured.
The foundation for this lies in digital technologies and Industry 4.0 approaches: automated set-up processes, modular production systems and networked planning tools are crucial for keeping costs and lead times within limits.
Technologies & digital prerequisites for Lot Size 1
The following technologies are essential for achieving economical single-item production:
- Digital factory & smart planning systems: Production planning must be flexible and variant-capable. MES systems access real-time data and, for example, predict machine utilisation or set-up times – often using simulation (CAx) and templates.
- Condition monitoringContinuous monitoring of machine condition through sensors for early detection of wear and defects. & in-line quality control: Continuous monitoring of tools and processes ensures product quality despite high variety. Sensors and automation provide rapid feedback.
- Digital twins & standardised data models: Digital twins allow simulation before production. Unified data structures across machines (keyword: standardisation) function without manual intervention – a typical Industry 4.0Fourth industrial revolution through digitalization and intelligent networking of production facilities. scenario.
- AI-supported decision-making: AI-based tools analyse production processes, optimise set-up sequences, material flow and resource allocation in real time – essential for efficient Lot Size 1 production.
These technologies form the backbone of agile single-item manufacturing – only then can Lot Size 1 be implemented economically.e single-item manufacturing – only then can Lot Size 1 be implemented economically.
Lot Size 1 in logistics and the supply chain
Companies also face profound changes in logistics:
- Dynamic and agile supply chains: Companies must respond flexibly to individual orders – requiring transparent processes and proactive communication across the entire supply chain.
- Minimal stock, rapid response: Single-item production demands near-zero inventories. Logistics must deliver quickly, usually with next-day or same-day delivery. Picking technology and infrastructure are streamlined for efficiency.
- Digital networking & Logistics 4.0: Networking of all logistics processes (6R principle), the use of autonomous vehicles (AGVs), digital twins and IoT technologies enable flexible intralogistics – particularly for changing individual orders.
- Supply chain transparency & collaborative networks: Efficient Lot Size 1 production requires all partners along the supply chain – from suppliers to end customers – to be closely connected and to share relevant information in real time.
Further information and links
- WSW Software – Lot Size 1: Requirements & Implementation (English) – Requirements in IT, organisation and process management
- DHL Freight – Lot Size 1 and Mass Customisation in logistics – logistics challenges and digitalisation
- Wipro – Digital Manufacturing for Lot Size 1 – digital factory for flexibility
- Siemens Blog – Industry 4.0: Is Lot Size 1 Achievable? – digital twins and standard data as enablers
- Mindlogistik – Lot Size 1 know-how – fundamentals, significance and strategies