Marek Piatkowski. December Marek Piatkowski FSP Consulting

Transcription

1 Materials Strategy Milk Run Tugger Deliveries ntroduction Marek Piatkowski December

2 2

3 3

4 4

5 5

6 6

7 7 7

8 8

9 9

10 10

11 Delivery Method Design Principles 11

12 Why Change? Original Condition Tugger Condition T-Car. AC AC T-Car 921 Sup. T-Car Janet 12 mm Sup. 12 mm 11 mm Vendor 11 mm Sup. DAH DAH Cevt. Ball Storage D Rec. nsp A 952 Spring B 972 Brutor Area C Supl. Rec. nsp GF Manuf. Services Penny Sat 846 T-Car. AC AC T-Car mm 11 mm DAH Cevt. Ball Storage D Rec. nsp A 952 Spring B 972 Brutor Area C 3 day 3 day 3 day 3 day 2 carts 800 of matl. 1 hr 45 min in a tour Sat 846 AC Short AC Sup. Supermarket Roller AC Short Proposed value stream small components to assy. lines Sat Short Short Asst Sat Short Short Asst 12

13 Two Methods of Delivering Material 1. Fixed Time Random quantity delivery 2. Fixed quantity Random time delivery Signal lamp WKB Flow Rack WKB Kanban Post 45 minute repeating loop Store WP for feeding the machine 15min. Trigger point Kanban Post WKB WKB On a set and timed route e.g. 45 minutes the material handler will pick up the Kanban cards and deliver product line side n response to inventory decreasing below the trigger point, the material handler brings a fixed quantity e.g. two boxes to the line 13

14 Tugger Deliveries - Design Principles Two types of material delivery systems: Time based (regular schedule) - deliveries based on a regular schedule, Milk Run Random based - deliveries based on a as needed signal 14

15 Creating information flow - Delivery Decide on a delivery method: Time based Milk Run or random deliveries Small container vs bulk container Standard Work for Material Handlers dentify frequency of deliveries What signal to use Decide on the Point-of-Use inventory levels How much inventory to keep at the line. Use PFEP. How much inventory to deliver each time 15

16 Creating material flow - Delivery dentify a delivery route Material pick up and delivery points List of material to delivery at every point Map out the delivery route Disposal of returnable containers and trash Verify readiness: of each part for the delivery of delivery equipment of each pick up point Warehouse/Supermarket of each delivery point Line/Work Cell 16

17 Operating Principles All deliveries and material handling conducted only by designated people from the Material Handling department NOT production operators Empty or returnable containers are picked up by the Tugger and delivered to the warehouse - NOT to the Supermarket. Delivery Kanban cards must be collected on regular basis and returned to the Supermarket. All material taken from the Supermarket must be delivered and left at the Line. No material is returned to the Supermarket. Take only what you need. No Kanban (signal) no delivery 17

18 Operating Principles (Con t) All delivery routes must be well defined and standardized Point-of-Use racks and WP markets to be located along main delivery routes to allow timely delivery system Point-of-Use storage locations well designed and located near main delivery routes All parts and components delivered to the line must be operators ready boxes open, all packaging material removed All material must be stored on designated racks. No material to be stored on the floor or in the isles An attempt should be made to minimize Forklift traffic between warehouse and assembly lines or work cells 18

19 Tugger Deliveries - Design Principles There are two ways of loading and unloading Tugger: Coupled (1 Operator) Tugger driver loads the carts in the Supermarket and delivers parts to the point-of-use. De-Coupled (2 Operators) One Operator is Tugger driver only delivering parts Another Operator is a Supermarket Attendant who loads the carts in the Supermarket. 19

20 Lean Transformation Solutions Marek Piatkowski F.S.P.. Consulting nc. VM: Cell: