Making Materials Flow (1 Day Class)
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Description:
This workshop will teach you how to create a material movement and handling system for purchased parts from the receiving door to the shipping door. It focuses on how to transition from a mass-production material-handling system to a lean system that reliably supplies purchased parts to continuous-flow cells, small-batch processing, and traditional assembly lines.
Benefits:
You’ll learn how to implement a lean material-handling system for purchased parts that delivers precise quantities of parts, precisely when they’re needed, to precisely where they’re needed – the fingertips of production operators.
The benefits of a lean material-handling system include:
- Fewer material handlers
- Less time spent by operators retrieving parts
- Higher plant inventory turns
- Less inventory
- Fewer forklifts
- Less forklift recordable incidents
- Higher production output
- Less overtime
- Less expedited delivery costs
Learning Objectives:
At the end of the workshop you should be able to:
- Create and populate a PFEP (Plan For Every Part)
- Understand how to develop and operate a supermarket for purchased parts
- Calculate an appropriate number of kanban cards using a given formula
- Determine route travel time for system standardization
Note: This workshop will not go into detail on the plant-to-plant side of material movement.
Course Outline:
Through instruction, discussion, video, and hands-on workshop exercises, this workshop uses a realistic manufacturing video and factory example to step you through the implementation sequence and the use of formulas, forms, and rules so you know “what to do Monday morning” when you return to work. The instructor will also lead you through the formulas for calculating the number of kanban cards, rules for designing internal routes and determining route travel times, and how to sustain and improve the system with standard work.
This workshop transfers to you the knowledge and tools needed to develop an efficient, reliable material-delivery system for purchased parts in a lean environment. You'll learn a step-by-step method for developing and implementing a facility-wide system that supports continuous flow. Workshop contents include:
- Why is a material delivery system necessary
- Where to begin the implementation
- What is a Plan For Every Part (PFEP)
- How to compile the PFEP information
- How to size a purchased parts supermarket
- Maximum and minimum inventory levels
- The types of pull signals
- How to get parts from a supermarket to manufacturing
- Different conveyance devices
- Standard work for the materials department
- How to calculate the time it takes to deliver material
- How to sustain the changes
The key steps detailed in the workshop include:
- Developing the Plan For Every Part (PFEP)
- how PFEP fosters accurate and controlled inventory reduction
- why this is the foundation for the continuous improvement of a facility’s material-handling system
- Building the purchased-parts market
- eliminate the waste of hoarding, searching for parts, and storing inventory throughout a facility
- learn the formulas and methods to size and operate the market
- Designing delivery routes
- learn the principles and calculations to designing the routes
- turn a sprawling, messy plant into an organized community where operators get the parts they need–when needed and in the quantity needed–delivered right to their fingertips
- improve not only inventory and flow but also safety and housekeeping
- Implementing pull signals
- allow operators to pull just what they need while focusing on producing value for customers
- learn four steps to creating a pull system, keeping inventory under control
- lean how to calculate the number of pull signals needed and how often to deliver material
- Continuously improving the system
- systematically pursue perfection by implementing periodic audits of the material-handling system across all levels from route operator to plant manager
- learn the five-step process for introducing audits of the market, routes, and pull signals by a cross-functional team from production control, operations, and industrial engineering
Who Should Attend:
Those who would benefit from attending this workshop include:
- Production control and material-handling personnel, engineers, managers, supervisors, operations and support personnel, and change agents
- Organizations that have processes requiring purchased parts for production
- Organizations that have had experience with value-stream mapping as well as implementing lean in other areas of their organization
To maximize your learning experience we recommend that prior to attending this program you take following workshop or have a good understanding of the concepts presented within it.
Price: $800.00 ($700.00 if the participant is taking 2 or more workshops at one location)
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