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MAN02 - Lean Manufacturing

MAN02 - Lean Manufacturing. Darren Hogg – WIKA Instrument Corporation dhogg@wika.com. Questions. How many toilets in your house? Lean in our lives… KanBan Are you back flushing? How do you manage low cost items? Do you cycle count?

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MAN02 - Lean Manufacturing

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  1. MAN02 - Lean Manufacturing Darren Hogg – WIKA Instrument Corporation dhogg@wika.com

  2. Questions • How many toilets in your house? • Lean in our lives… • KanBan • Are you back flushing? • How do you manage low cost items? • Do you cycle count? • How much material do you need at the cell? How often do you replenish?

  3. Questions • Do KanBan’s work on long lead-time suppliers? • How does Lean work when you forecast? • ATP integration? • Lean Accounting? • Is Sales connected to manufacturing? • Can you wait for MRP? • Do you run coverage by warehouse

  4. Why go to Lean Software? KPIs and Management reports Bull-whip management throughout the entire supply chain Historical data to analyze and continuously improve inventory levels, supplier performance, etc. MRP integration for mixed-mode environments and to support S&OP Resource requirements visibility through drumbeat and takt time calculations • Transparency throughout the entire organization • Kanban Calculations straight from customer demand and automatic integration with Kanban levels • Kanban Portals to seamlessly communicate Kanban Requirements externally in real time • Visibility of critical inventory situations • Pull directly from source of demand

  5. Released Modules – AX 2009 Organization Planning /Scheduling Kanban and Pull based execution Lean Accounting Cells LOS(Lean Order Schedules) Kanban Kanban Board Value Stream as a financial Dimension LOS Schedule Hierarchies Heijunka Board SubcontractingKanban Kanban Inventory Overview Black Hole Sales Pull Signals (LOS BTO, PTO Kanban, Calloff) Takt Meter Sales Schedules Cost Substitution Purchase Kanban Bar codes Manufacturing without Production Orders Withdrawal Kanbans

  6. Lean Manufacturing is Pull Kanban and Lean order modules provide a huge range of features to map pull and push scenarios for the complete supply chain : • Manufacturing • Replenishment • Purchase • Subcontracting

  7. AX Lean Manufacturing is Build to Order • Build it where it is needed, when it is needed • Managing high number of variants with low WIP • Lean Order Scheduling based ATP • Drumbeat control • Multi Level Build to Order • Pull to Order Kanban BTO Kanban Production Flow

  8. AX Lean Manufacturing is Visual

  9. KanBan Management • An electronic ‘ticket’ that signals a ‘pull’ of an item to supply a Buffer • Manufacturing (including Subcontracting) • Purchase • Replenishment • Fixed • Target • Pull-to-Order • Dynamic • Full barcode scanning integration

  10. Level scheduling (Heijunka) • A direct pull from a sales order to the cell • Level production by use of drumbeat scheduling • Pull can be transmitted to supplying cells and warehouses • Feeder Cell schedule • Pull-to-Order KanBan • Execute and receive production direct to schedule • Full barcode scanning integration

  11. Heijunka Planning Board

  12. Lean Accounting • Value Stream Accounting

  13. Lean Accounting • View Inventory by Value Stream

  14. Mixed Mode Planning & Execution Purchase Order Supplier KanBan Master Planning / Production Orders Heijunka Leveling Material Issue/ KanBan MRP/ KanBan Forecast Sales Order Schedule Call off KanBan Product Orders / Jobs KanBan

  15. Summary • Achieve demand-driven production • Increase replenishment efficiency • Accelerate continuous improvement • Understand value streams, eliminate bottlenecks, and identify improvement opportunities • Free people for higher-value activities

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