P
Pinball
Hello Everybody!
Even I spent the last days reading through all kinds of threads about LEAN, WIP, KANBAN,... I was not able to think about a proper solution for my problem:
We assemble different kinds of our product at about 30 production lines whereas some production lines have up to 10 projects, some have only two. Every product has about 28 parts (small and big parts). The output per shift is about 300 pieces/production line. We want to implement Kanban because of the limited space and the current disorder when ordering parts by phone or elsewise. Therefore we chose one line to be the prototype. It has two projects; high runner (4 days a week) and a low runner (production 1 day/week).
Problems with the common small/bulk parts:
Within this factory several production lines (often the same customer) are combined into one Store Location (SAP). As such the factory consists out of five store locations. The store location that includes the prototype line has about 10 common parts (a screw, a rubber, ...), but not every one out of the ten uses every common part!
Whenever common parts are released to one production line by SAP, it will only release further material if the "old" material is used up. If the worst comes to the worst (one production line stops and another would need the same part), operators would have to move common parts from one line to another. Right now, only 5 lines are operating. Since we want to use Paper Kanban that has includes an WIP ID which identifies the location in the material shelf, the Kanban cannot leave the production line! Otherwise the information on the Kanban would not be right anymore.
We came up with the following ideas:
->"A moving, shared supermarket": Setting up a table, sized 1x1m, visualizing all lines and common parts within one store location. This table would be located between warehouse and production for the material handlers. We would use magnets to indicate the location of the common parts box within the store location. In this case the material handlers can track the box to its origin. When they move the box, they would remove the "old" Kanban to the material shelf(every line has a small shelf for small parts) of the production line and replace it by the new Kanban that came from the production line, ordering parts. And as such he would transfer the box to the line. All involved workstations have a buffer for these parts that lasts about half a day (+/- not all of them have the same buffer).
->We drop all the small parts and push to the line and only use Kanban for about 5 of the 28 parts to continue the habbit.
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I see the whole project in danger. I am convinced that it would be the best solution to implement Kanban as a whole and not chopped nevertheless the system is flexible in its realization.
Thanks to everybody who wants to share the burden and puts on the thinking cap!!!!
Have a nice weekend!
Even I spent the last days reading through all kinds of threads about LEAN, WIP, KANBAN,... I was not able to think about a proper solution for my problem:
We assemble different kinds of our product at about 30 production lines whereas some production lines have up to 10 projects, some have only two. Every product has about 28 parts (small and big parts). The output per shift is about 300 pieces/production line. We want to implement Kanban because of the limited space and the current disorder when ordering parts by phone or elsewise. Therefore we chose one line to be the prototype. It has two projects; high runner (4 days a week) and a low runner (production 1 day/week).
Problems with the common small/bulk parts:
Within this factory several production lines (often the same customer) are combined into one Store Location (SAP). As such the factory consists out of five store locations. The store location that includes the prototype line has about 10 common parts (a screw, a rubber, ...), but not every one out of the ten uses every common part!
Whenever common parts are released to one production line by SAP, it will only release further material if the "old" material is used up. If the worst comes to the worst (one production line stops and another would need the same part), operators would have to move common parts from one line to another. Right now, only 5 lines are operating. Since we want to use Paper Kanban that has includes an WIP ID which identifies the location in the material shelf, the Kanban cannot leave the production line! Otherwise the information on the Kanban would not be right anymore.
We came up with the following ideas:
->"A moving, shared supermarket": Setting up a table, sized 1x1m, visualizing all lines and common parts within one store location. This table would be located between warehouse and production for the material handlers. We would use magnets to indicate the location of the common parts box within the store location. In this case the material handlers can track the box to its origin. When they move the box, they would remove the "old" Kanban to the material shelf(every line has a small shelf for small parts) of the production line and replace it by the new Kanban that came from the production line, ordering parts. And as such he would transfer the box to the line. All involved workstations have a buffer for these parts that lasts about half a day (+/- not all of them have the same buffer).
->We drop all the small parts and push to the line and only use Kanban for about 5 of the 28 parts to continue the habbit.
---------------------------------------------------------------------------------------------
I see the whole project in danger. I am convinced that it would be the best solution to implement Kanban as a whole and not chopped nevertheless the system is flexible in its realization.
Thanks to everybody who wants to share the burden and puts on the thinking cap!!!!
Have a nice weekend!