Hide Categories  Government  Forums FAQ  Forums Feedback  Lean in Education  Lean Theories and Dialogu...  Manufacturing  Business Process  Healthcare  Supply Chain  Service  Inactive Topics 08/97~06/...    Specify Value    Mapping    Flow    Pull    Perfection    Change Management Search Forums advanced search

FORUMS Supply Chain Eliminating Cycle Counting Topic Title: Eliminating Cycle Counting Topic Summary: Eliminating Cycle Counting on low cost parts Created On: 12/29/2011 05:41 PM Linear : Threading Send to a Friend Search Topic Keyword Topic Tools View similar topics Print this topic. 12/29/2011 06:29 PM BillCaskey Bill Caskey Hi, I am working on reducing waste in our cycle count program. Does anyone have any references on justifying the elimination of cycle counting parts that are on Kanban replenishment. We are cycle counting washers that are $10 for a thousand of them and they don't even trigger our weigh scales. We also have some parts such as our powder coating that never backflush in the system accurately do to very slight inaccuracies in BOMs versus application of the powder. The system therefore is never accurate yet we cycle count the material for no apparent purpose. Thanks Reply : Quote 12/30/2011 11:06 AM Chuckster Charles (Chuck) Intrieri Hello: You might try VMI (Vendor Managed Inventory) on small, "C"items, "fastener" components. As for powder coating, what does your system state: pounds, bags, ? Perhaps the item Master can be changed, unit amount, to make cycle counting easier? Chuck Intrieri ceebees64@cox.net Reply : Quote 01/03/2012 11:08 AM BillCaskey Bill Caskey Thanks Chuck for replying, Our powder coat material is maintained in pounds and is consumed in our BOM's as portions of pounds with the "best" guess of our engineers. The fact is that accuracy of the usage is poor due to the variations in thickness within the tolerance of the product specifications. In addition depending on product mix the coating gun lines must be purged as we change from one color to another. I will look into the references you gave on the low cost parts. Thanks Bill Reply : Quote 01/04/2012 01:58 PM AdamM Adam Malec Are you counting each washer or the whole box? If the box comes in and is, as long as you don't pick from it, you shouldn't have to count the whole box, just write down what the quantity of the box is. If there is a part picked box then yes, you might have to count it. There are few reasons why cycle counting is required which include: 1.) Legal - for audit purposes 2.) Product is owned by the customer 3.) Product availability for production All in all, you should still cycle count because you don't want to get to a situation were you run out of parts even though you think you might have 1,000 in the warehouse. But, it does not have to be intensive and hard for yourselves. Reply : Quote FORUMS : Supply Chain : Eliminating Cycle Counting Topic Tools

Note: These forums are moderated by the Lean Enterprise Institute. All posts are reviewed prior to appearing on the site. Views expressed in these forums do not necessarily represent the views of the Lean Enterprise Institute.