StockSAVER new third generation Kanban system

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1 WERMA Signaltechnik GmbH + Co. KG Dürbheimer Str. 15 D Rietheim - Weilheim Phone Fax info@werma.com WERMA Signaltechnik Niederlassung Neuhausen am Rhf. Rheingoldstrasse Neuhausen am Rheinfall Switzerland Phone Fax info@werma.ch WERMA SARL 56, Rue Colière Mions France Phone Fax info@werma.fr WERMA BENELUX bvba Industrieweg Bus Wondelgem Belgium Phone Fax info@wermabenelux.com StockSAVER new third generation Kanban system StockSAVER WERMA (UK) Ltd. 11 Regent Park 37 Booth Drive Park Farm Industrial Estate Wellingborough NN8 6GR Great Britain Phone Fax uksales@werma.co.uk WERMA USA Inc Collamer Road East Syracuse, NY USA Phone Fax us-info@werma.com WERMA (Shanghai) Co., Ltd. No. 8, High Technology Zone, No. 503, Meinengda Road, Songjiang, Shanghai, P. R. C China Phone Fax info@werma.com.cn 03/ E

2 EUROPE S LEADER IN SIGNALING Contents Introduction Pages 4-5 Features and benefits Pages 6-9 The system Pages StockSAVER references Pages 14-15

3 StockSAVER TAKES YOU INTO THE NEXT GENERATION StockSAVER represents the latest generation in Kanban systems for production logistics. Simple to retrofit to FIFO flow racks, StockSAVER solves many of the traditional Kanban problems, frees up space for more value adding activities and improves cash-flow. StockSAVER calls up material replenishment orders automatically, thus eliminating the margin for human error and making the need for line-side safety stocks redundant. Winfried Huber, Sales Director WERMA Germany 4 5

4 StockSAVER: THIRD GENERATION KANBAN SYSTEM StockSAVER A ROBUST SYSTEM First generation - Kanban cards Problems: Delays in handing over cards, cards mislaid or not collected by milk-round, too little transparency. Second generation - Use of scanners Problems: Disruption through incorrect bookings, forget to scan, incorrect stock in the racks, system world not identical with reality. Third generation Scanning to create replenishment orders not required No more double entry bookings See the actual stock-holding in real-time Arithmetic errors in counting stockholding eliminated Replenishment bins are placed in the correct location StockSAVER ENABLES YOU TO REDUCE SIGNIFICANTLY FIFO FLOW RACKING SPACE Frees up space on the shop-floor for value adding activities Reduced stock holding means flow racks can be shorter/smaller Fewer bins per shelf required Low margin + = for error Third Generation Kanban System RESULT Reduce safety stocks held on FIFO racks and thereby improve cash-flow. Automatic and immediate notification of demand for replenishment Sensors pick up the actual stock holding on shelves Human errors eliminated and traditional Kanban problems resolved (Stock-outs cannot occur, Kanban cards are not lost or forgotten etc.) Significant reduction in stock held line-side possible StockSAVER ALLOWS YOU TO REDUCE STOCKS Protects against material running out Save space by not having to carry emergency stocks Reduce safety stocks, even with wide variety of parts The digital Kanban board gives a comprehensive real-time view of stock and requirements which facilitates the prompt replenishment of material. 6 7

5 KEY FEATURES AND BENEFITS OF StockSAVER: BENEFITS Optimise stock Significant reduction in stock held is possible. Transparency Sensors on the FIFO shelves give complete transparency which is then displayed on the Kanban board. IMPROVE CASH-FLOW Reduce stock levels and improve cash-flow Emergency stocks no longer necessary Get to grips with safety stock levels, even with a high variety of parts Resolve problems Traditional Kanban problems are resolved and the margin for human error eliminated. Improve resource More space for value adding activities. REDUCE ERRORS Robust system solves traditional Kanban problems such as mislaid Kanban cards Scanning not required replenishment is called up automatically No duplication of bookings Flexible, allows prompt reaction in real time Parts cannot be placed in the wrong rack location Improve cash-flow Lower stocks leads to improved cash-flow. REDUCE SIZE OF FLOW RACKS SIGNIFICANTLY High variety of parts Low stock-holding requirement, even with high variety of parts. Reduce size of FIFO racks and save space. Safety stocks no longer required without running the risk of stock-outs. More space on the assembly line. Create space for value adding activities. 8 9

6 SENSOR Detects the number of bins and transfers this data to the SensorBOX. TRANSCEIVER Receives the status of the SmartBOXES and transfers this data to the StockSAVER software. SensorBOX Receives data from up to four bins per shelf and transfers this data to the SmartBOX. SOFTWARE Gives total transparency to all networked FIFO flow-racks. SmartBOX Receives data from the SensorBOXES and transmits this wirelessly to the Transceiver. OPTION: A barcode scanner can be used which will detect incorrect replenishment and insist on correction of the error. THE SYSTEM StockSAVER is simple to install or retro-fit and monitors the stock-holding in your FIFO flow racks. Data monitored is transmitted wirelessly and processed by the software which is supplied with the package. You will have lasting benefits from the data enabling you to improve your processes for material movement and replenishment. The Kanban board displays which h location requires replenishment. SENSOR SensorBOX SmartBOX TRANSCEIVER 10 11

7 INTUITIVE AND COMPREHENSIVE THE StockSAVER SOFTWARE The simple windows-based software supplied with the system is easy to install. Step by step the software will help you to mirror your existing flow racks with the right parts on the right shelves and the required number of bins per shelf to optimise your stock levels. This gives you complete transparency of the available stock at the workstation. The requirement list informs logistics promptly of a material requirement and its priority. Data collected will enable you to make improvements to your processes. GET TRANSPARENCY CONTROL STATION This is where you get a complete overview with a digital version of the status of your FIFO flow racks at the work station. The data displayed makes safety stock unnecessary which in turn means you can save space on racking and use it instead for other value adding activities. GUARANTEE REPLENISHMENT REQUIREMENTS LIST As soon as a bin is moved the requirements list is updated guaranteeing speedy and prioritised replenishment. Manual errors, such as mislaid Kanban cards or failing to register stock-outs, become things of the past. IN THE PICTURE ALL THE TIME A number of real-time displays continually inform you of stock levels and replenishment requirements at all monitored flow racks. Collection of Kanban cards is unnecessary as Logistics will receive automatically a rolling to-do list which is timed and prioritised. In this way the margin for human error can be reduced, the replenishment process is speeded up and high levels of safety stock made unnecessary. IMPROVE PROCESSES ANALYSIS Analysis is the best means of making long-term improvements to processes. Whether it is the identification of spikes in demand, selecting the optimum bin size or simply identifying how often a stock location is being replenished, the reports function will provide all of this at the touch of a button. STOCK MOVEMENT DATA EXPORT INTERFACE FOR UPSTREAM LOGISTICS PROCESSES Stock movement data can be exported and be used, for example, to initiate new production orders or make material bookings. This provides an important interface with your broader operating system

8 WHAT OUR CUSTOMERS SAY: STEFFEN MOSER, RESPONSABLE LEAN, SCHMIDT TECHNOLOGY: StockSAVER is easy to use and understand and does not lead to over-complication of the process. Implementation worked really well thanks to the excellent and intuitive assembly and installation instructions. We will certainly be using StockSAVER in our new production facility. MANUEL SEELAND, SCM PROCESS & SYSTEM DEVELOPER: Using StockSAVER has shown us how to screw back on stocks held safely. StockSAVER: BECAUSE IT MAKES SENSE Countless numbers of customers are already using and enjoying the benefits of WERMA systems and making their operations safer, more efficient and more lean. Further information on StockSAVER including application information and videos can be found on our website: SILVIO SPRENGER, PRODUCT MANAGER SENSOR SOLUTIONS: We use materials with use by dates so consequently we carry just minimum stocks using StockSAVER makes sense and gives us security. FIND OUT MORE ON THE WEB-SITE 14 15

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