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KANBAN &SUPERMARKETS

KANBAN &SUPERMARKETS. What is Kanban?. Kan – card ban – signal Concept is supplier or warehouse should only deliver components to the production line as and when needed. Limits inventory by only responding to the signal Normally Visual – transport (simple) or production (integrated)

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KANBAN &SUPERMARKETS

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  1. KANBAN &SUPERMARKETS

  2. What is Kanban? • Kan – card ban – signal • Concept is supplier or warehouse should only deliver components to the production line as and when needed. • Limits inventory by only responding to the signal • Normally Visual – transport (simple) or production (integrated) • Parts/material is the “Supermarket”

  3. Supermarket Setup Process • Products defined • Value Stream Maps completed • Supermarket or work flow stoppage • Flow layout completed • 5S (Including complete parts inventory) • Conducted data collection • Calculated supermarket size plus $$$ • Design the supermarket

  4. Supermarket setup cont. • Determine replenishment strategy • Stock System, IDTC, DVD, Credit Card, Internal supplier, etc • Follow NEMAIS structure • Train everyone • Audit and improve • Requires TEAM APPROACH

  5. Supermarket integration into process • Standard Work Package • Standard Work Practice in work area • Note: standard work package does not necessarily lead to standard work practices!! • Fixed material cost for std work • Second tier parts • Product pricing established • Add cost to capabilities manual

  6. Keep It Simple! - The Calculation Don’t let the “Exceptions” stop you Average Daily Use X Lead-time X Safety Factor (1.5) = Signal Level

  7. Planner does not order any material. • NEMAIS can be set for auto re-order • Maintenance team budget for I level based on product cost. • Funding based on dedicated Supermarket per product.

  8. Current/Future Supermarkets • True supermarkets in only a few production shops, others in various stages of development • 25MM, VLS, CIWS, SRBOC, Inside Rigging, Pump, Valve,O/S Machine, Structural • No efforts underway in “D” level process. LSD 41 engine repairs prime example

  9. Supply Chain Management • What is SCM? • Why is SCM important? • How does it tie into Continuous Improvement? • What are the cost? People/NVA • Alternatives? • Systems Thinking

  10. NEMAIS Works Great If : • You can accurately forecast by Part Number your next year’s requirements • You can accurately track and then predict station by station and component yields • You can accurately make ALL your computer transactions (if you 100% inspect a • process – what is the statistically expected outcome? Do you inspect your transactions?) • You have and continue to maintain an accurate Bill of Materials (Alternate parts not even • considered) • You can determine and maintain accurate Lead times VERY, VERY IMPORTANT • There are NO resource constraints at your or your vendors factory • Engineers or those pesky Technicians NEVER steal any parts for CASREPs etc. • You have trained your customers to “buy” what you have planned • You have an excess amount of cash to pay the additional staff you need to track and maintain • the above • You have extra storage space you want to fill up

  11. Simplified Cost Accounting By Product “Families” Labor Material Overhead Saleable Units Produced = Unit Cost

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