lean supermarekt principles - november 2016
TRANSCRIPT
Supermarket Principles Introduction
Thinking win, Win, WIN
Supermarket PrinciplesDefinitions
Marek Piatkowski – November 2016
Thinking win, Win, WIN
Supermarket Principles Introduction
Thinking win, Win, WIN
Introduction - Marek Piatkowski Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994
TPS/Lean Transformation Consulting - since 1994 Professional Affiliations
TWI Network – John Shook, Founder Lean Enterprise Institute (LEI) – Jim Womack Lean Enterprise Academy (LEA) – Daniel Jones CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
Supermarket Principles Introduction
Thinking win, Win, WIN
Supermarket in Manufacturing
Supermarket Principles Introduction
Thinking win, Win, WIN
The Supermarket Suppliers
Supermarket Principles Introduction
Thinking win, Win, WIN
Pull System In a traditional operation Production Scheduling department
generates Information by issuing schedules to all departments to produce and to move material.
Toyota reversed that process. At Toyota only material movement generates Information Flow - A Pull Signal (Kanban).
When parts are “pulled” from the Supermarket, a signal (Kanban) is sent to the supplying process to produce more.
Schedule is issued only to the Pacemaker process. This is called a Pull System.
Supermarket Principles Introduction
Thinking win, Win, WIN
Flow in Manufacturing must be in Real Time
Supermarket Principles Introduction
Thinking win, Win, WIN
Purpose of a Supermarket The purpose of a Supermarket is to create a buffer of inventory
(Purchased Parts, sub-assemblies or Finished Goods) in order to safeguard against process or delivery variations
Process variation can be caused by: Batch (large lot) production process Variation in working hours Equipment breakdown or problems Etc …
Delivery variation can be caused by: Large lot and non-frequent deliveries Transportation costs and distance Delivery schedule changes Weather Etc …
Supermarket Principles Introduction
Thinking win, Win, WIN
Warehouse vs. Supermarket In a supermarket we stock only items that are
frequently needed by its customers when they are needed and in a quantity needed We do not stock Make-to-Order parts in the Supermarket
Supermarket is a Supermarket only if: All parts kept in a designated location – easy to pick All parts kept in designated Line-ready containers – no repacking All parts and containers are clearly identified Min and max levels of inventory (number of containers) are defined Parts are replenished several times per day FIFO (first-in-first-out) is in place Lot control, when applicable, is in place
Supermarket Principles Introduction
Thinking win, Win, WIN
Supermarket and Lean Transformation Supermarket is NOT a final stage of Lean Transformation Supermarkets are constructed at the beginning of Lean
Transformation in order to: Stabilize the operation by eliminating parts shortages “Protect the Customer” – short Lead Time and 100% on time
Customer deliveries Gain control of inventory problems – not enough of what we need
and too much of what we do not need Ideal State is - No Supermarket !!!
Sequential Delivery (Just-in-Time) - deliver parts and components to the Customer, in a sequence and mix they require, minutes before they are needed at a manufacturing site
Therefore, the little inventory that exists would be a ‘rolling inventory” delivered frequently to point of use in the manufacturing line
Supermarket Principles Introduction
Thinking win, Win, WIN
Levels of Supermarket Development
Basic warehouses in place, if any Poor or no inventory control Ongoing problems with parts shortages and customer deliveries Information flow does not match material flow Frequent inventory counts and adjustments Poor or no material organization in the facility No visual management Multiple storage location for same part number etc..
Level 1 – NO Supermarket / NO Mini-Markets in place
Supermarket Principles Introduction
Thinking win, Win, WIN
Levels of Supermarket Development
Basic organization of material in place Most of the material located in one place No Mini-Markets – delivery points not well defined and
controlled Some visual management in place
Level 2 – Basic Supermarkets / NO Mini-Markets in place
Supermarket Principles Introduction
Thinking win, Win, WIN
Levels of Supermarket Development
Level 3 – Supermarkets / Mini-Markets in place Common parts Supermarket with segmentation for unique or make-
to-order parts Single (designated) part locations Good visual management in place – inventory control Daily meetings in front of Information Boards Mini-Markets (with less than few hours of inventories) in place Frequent and structured deliveries to Mini-Markets or
Point-of-Use locations Incidents of “Parts Shortage” are rare
Supermarket Principles Introduction
Thinking win, Win, WIN
Levels of Supermarket Development
Level 4 – Supermarket Eliminated / ONLY Mini-Markets in place
Common parts Supermarket eliminated Only unique or make-to-order parts stored in the
Supermarket Mini-Markets through out the facility Frequent and structured deliveries to Mini-Markets Inventory levels in hours
Supermarket Principles Introduction
Thinking win, Win, WIN
Levels of Supermarket Development
Level 5 – Ideal State Just-in-Time Deliveries
No Supermarkets Mini-Markets replace with Points-of-Use inventories Just-in-Time sequential deliveries of material to Points-of-Use Material Handling (Logistics) should be able to move parts and
components at pace of manufacturing in a right component model, sequence, and mix.
Inventory levels in minutes - not hours or days
Supermarket Principles Introduction
Thinking win, Win, WIN
Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
Supermarket Principles Introduction
Thinking win, Win, WIN
Presentations in this Workshop
1. Log in to: www.slideshare.net
2. Type in my name in search area:
Marek Piatkowski3. Select a
presentation you want to see
4. Learn and Enjoy