Easy OnBoarding Sizing Kanban Loops Easy OnBoarding Course

Easy On-Boarding Sizing Kanban Loops

Easy On-Boarding Course Overview • Introduction to Lean Manufacturing • Sizing Kanban Loops 2

What is Lean ? What are the fundamental concepts of “Lean Manufacturing”? What are the goals of Lean? What are the prerequisites to creating a Lean Environment? What is Takt Time and how is it used? What is the EPEI and how is it used?

Fundamental Concepts of Lean • Lean manufacturing has a single objective: “make value flow” • Lean manufacturing is a methodology or approach to manufacturing different from mass production or craft production • The approach to maximizing flow across the value stream is based on reducing or eliminating waste, unevenness or irregularity, and strain • Pull substitutes for flow when flow is not possible • “Pull” is based on the concept that when an item is consumed it should be replenished. Contrast this with “push” which produces an item in anticipation of demand • “Customer” demand, not forecasts are the primary driver for lean • Lean manufacturing does not mean “zero inventory” • In a pull system, inventory is limited and strictly controlled in managed “supermarkets”

Goals of Lean • Continuous flow from raw material to finished goods • Produce only the quantity needed • Build to order (production lead time shorter than demand lead time) • Basic Tools of Lean

Important tools of Lean: • • • Value Stream Mapping Takt Time EPEI Leveling (Heijunka) Pull Systems Setup Reduction Pokayoke (Mistake Proofing) 5 S Cell Design and Operator Balancing Quality improvement (6 sigma) Standard Work

Prerequisites Lean environment • Leveling (heijunka) both long term and short term • Standard work • Kaizen

What is Takt Time and how is it used • • • Pacemaker processes Takt time Operational takt time Important takt and operational takt time concepts Pitch

What is EPEI and how is it used • Definition • Objectives of the EPEI • How is the EPEI calculated ?

Easy On-Boarding Size Kanban Loops 10

Where Average Demand Is Used • The most important uses of the average daily demand in the QAD Lean module are: - Kanban Sizing Order Point EPEI Calculation (Order Quantity) Safety Stock Calculation Takt Time Calculation

Demand Calculation Template Maintenance

Demand Calculation Template Update

Assigning Templates to Loops • Demand Calculation Template Update Report

Average Demand Calculation

Average Demand Calculation Report

Kanban Workbench • key functions and its extended functionality - Seamlessly retrieves data from QAD Lean and seamlessly updates it once sizing is complete. - Calculates the EPE Interval for manufactured parts. - Provides for EPE Interval overrides by process (minimum) and by item. - Calculates the order point and order quantity considering average daily demand, replenishment lead time, safety stock and safety time, EPE Interval, tooling cycles, fixed ordering intervals, packaging constraints, management adjustments, etc. - Validates against user specified loading limits. - Includes analyst aids to show the impact on inventory holdings (units, dollars, coverage), safety stocks (specified as well as that generated by container and kanban sizes), etc. - Reconciles kanban cards after updating.

Kanban Workbench Selection Criteria

Kanban Workbench Process Master Data

Kanban Workbench Process Detail, Sizing, Analyst Data