Download - Holophane Materials Department Vision
Material Management
Vision
Material Management
Vision
Material Management PyramidMaterial Management Pyramid
MM - 3 Designated Storage
Agile/LEAN/Fast to Market
MM - 7 Supplier Delivery
MM - 5 Internal Pull Systems
3
4
6
Lean Enterprise Mfg. PC - L Engineering Purchasing Sales
BUSINESS PROCESSES ALL LINKED Customer order today - ship
today
Manufacturing System
Design Employee Environment
& Involvement Quality Workplace
Organization Operational Availability Material Movement
Support Communication Expectations Commitment Leadership Knowledge Planning Action
Education/Training Aligned Metrics Follow - up
The Foundation
2
1
7
5
MM - 4 Container Right Sizing and Supporting the Operator
Build to Order Modularity
Supermarket /Bulk Storage
Visual Management
Addressing Empty Container Storage
Standard Containerization
Small Lot
Common Lot
MM - 6 Internal Delivery Systems
Production Pull
Withdrawal Pull
Buffer Management
Standardized Routes
People Focused Practices
Changeover Process
Scheduled Window Receiving (Dock Boards)
Container Return Process
Supplier Pull
Frequent Delivery
Milk Runs
Scheduled Pickup
Pickup Sheets
Summary Billing
Lean Logistics
MM - 1 Plan for Every Part MM - 2 Ship to Schedule and Build to Plan
Maintenance Planning Production Leveling Small
Lot Buffer
Management Scheduled Window
Shipping (Dock Boards)
Overview
First StepFirst Step
Part NumberPurchase or MakeWeightStandard Pack QuantityContainer TypeContainer DimensionsSupplier NameSupplier LocationShip Frequency
Storage LocationStorage MethodVisual Min/MaxUsing LocationDelivery MethodAverage Rate of UsageUsage per Assembly
etc.
Database of All Part Numbers
Plan For Every Part is a material planning process that identifies/creates a detailed material flow plan for every part in the supply chain.
Production Leveling is used to create a production plan that levels the customer demand variation and
schedules production based on TAKT time of each line. AS400B-Line loading
0
100
200
300
400
500
600
700
800
Pastdue
21-Aug 22-Aug 23-Aug 24-Aug 25-Aug 28-Aug 29-Aug 30-Aug 31-Aug 1-Sep 4-Sep 5-Sep 6-Sep 7-Sep
Day
Un
its
AS400 Schedule
Production Plan
1 Shift Capacity
2 Shift Capacity
Cycle Stock
Safety Stock
Temporary Stock
Manufacturing and Demand Variation Stock
Max
Min
Cycle Stock
Safety Stock
Temporary Stock
Manufacturing and Demand Variation Stock
Max
Min
a buffer built and maintained for temporary conditions such as an engineering change, seasonal demand, part reallocation…
the buffer required based on frequency of manufacture and customer shipment; how frequently the part is produced and shipped
the buffer needed to protect from normal variation in daily production and customer demand
a buffer maintained to cover unplanned stock outages, equipment shortage or breakdown, tooling problems...
Supermarket/Bulk Storage
Second StepSecond Step
Supermarket/Bulk Storage is a designated area utilized to store material inventory (purchased, in-process and finished, both hand carriable and bulk).
Market Attendant picks carton based on Pull Card Order
Rack Label
Supermarket address Name
MAX 7 P90 Drum brake Adjusting screw
2
Row B
B C A
B C A
1 2 3 4 5 6 7 8 9 19 20 21 23 24 25 26 27 28 10 11 12 13 14 15 16 17 18
29 30
31
B2 C A
B C A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Column T64
Stocking Aisle Stocking Aisle
Stocking Aisle Stocking Aisle
Stocking Aisle Stocking Aisle
Picking Aisle Picking Aisle
Picking Aisle Picking Aisle D ROW
C ROW
B ROW
A ROW
D ROW
C ROW
B ROW
A ROW
Traffic Flow
Traffic Flow
Column T65
1 2 3 4 5
Row A
T64 A1 T64
A2
SUPERMARKET 2
Part number 22152297
Pack 60
MIN Suppli er XYD Ind.
T64 - A1 - A - 05
Pa rt # ___ __ ___ ___ __ __ __ ___ ___ __ _ D esc rip t io n_ ___ __ __ ____ __ __ ___ __ St d . P ac k__ __ ___ ___ __ ___ ___ __ ___ M i n_ ___ ___ __ ___ M ax __ ___ ___ __ __ St o re Lo c_ ___ __ _ U se L o c__ ___ ___ Su pp l ie r___ __ ___ ___ __ ___ ___ __ ___ D el iv ery D at e - M - T - W - T - F - S Ti me ___ ___ __ ___ ___ __ __ ____ __ ___ STORE AC 5 3
Pa rt # ___ __ ___ ___ __ ___ ___ __ ___ __ D esc rip t io n_ ___ __ __ ____ __ __ ___ __ St d . P ac k__ __ ___ ___ __ ___ ___ __ ___ M i n_ ___ ___ __ ___ M a x_ ___ ___ __ ___ St o re Lo c_ ___ __ _ U se L o c__ ___ ___ Su pp l ie r___ __ ___ ___ __ ___ ___ __ ___ D el iv ery D at e - M - T - W - T - F - S Ti me ___ ___ __ ___ ___ __ __ ____ __ ___ STORE Pa rt # ___ __ ___ ___ __ ___ ___ __ ___ __ D esc rip t io n_ __ __ __ ___ ___ __ ___ ___ St d . P ac k__ __ ___ ___ __ ___ ___ __ ___ M i n_ ___ ___ __ ___ M ax __ ___ ___ __ __ St o re Lo c_ ___ __ _ U se L o c__ ___ ___ Su pp l ie r___ __ ___ ___ __ ___ ___ __ ___ D el iv ery D at e - M - T - W - T - F - S Ti me ___ ___ __ ___ _ __ ___ ___ __ ___ __
STORE
1 2 3
Hand carriable Bulk
Container Right Sizing & Supporting the Operator is the process of packaging and grouping parts to best support the operator and meet the needs of the customer.
Containerization is the process of packaging parts in the smallest lot possible resulting in the presentation of a quality part to eliminate waste of motion for the manufacturing operator
Overview
Third StepThird Step
Internal Pull Systems serve as the nervous system for a value stream. They provide the instruction for the what is to be produced. Well-designed pull systems provide this instruction in a clearly defined simple to understand manner.
Internal Delivery Routes is a system to replenish material (purchased, in-process and finished goods, both hand carried and bulk) and remove empty containers based on a predetermined delivery path and fixed start times supporting pull delivery to a specific number of production delivery points-of-use.
InternalDelivery Route
12345
7 8 9
6
12345
7 8 9
6
C1
C2
Overview
Forth StepForth Step
Supplier Delivery is the process of managing materials received from suppliers and materials returned to
suppliers (containers and dunnage).
Supplier Pull is a process that uses pull signals based on consumption to authorize replenishment of material from suppliers.
Suppliers