Kanban for the Supply Chain : Fundamental Practices for Manufacturing Management

by Cimorelli; Stephen

• ISBN13: 9781563273148
• ISBN10: 1563273144
• Edition: CD
• Format: Paperback
• Copyright: 2005-10-31
• Publisher: Taylor & Francis

Summary

This workbook for manufacturing supply chain management (SCM) professionals illustrates how to apply kanban replenishment systems and improve material flow. Those who are now ready to make the conversion from materials requirements planning (MRP) push techniques to kanban pull techniques must read this book! In Kanban for the Supply Chain: Fundamental Practices for Manufacturing Management ., Stephen Cimorelli provides SCM teams with a roadmap for installing fundamental kanban concepts - the method is immediately actionable thereby increasing manufacturing productivity and profitability. Through an iterative process of planning, adjusting, and executing, kanban pull techniques keep inventory levels synchronized with demand, and the supply chain synchronized with actual production.

Table of Contents

Acknowledgments	ix
Introduction	xi
Workbook Outline and Style
Overview of Kanban in a Lean Environment	1	(18)
What Kanban Does	3	(5)
Definitions---Building a Common Language	8	(1)
Building a Lean Environment	8	(5)
JIT Preparation for Kanban	13	(6)
Supply Chain Management Fundamentals	19	(6)
Defining the Supply Chain	19	(1)
What is Supply Chain Management (SCM)?	20	(5)
Applying the ABC Classification	25	(6)
Applying ABC Classification Step by Step	27	(4)
The Saw Tooth Diagram---Analyzing Inventory Behavior	31	(8)
The Saw Tooth Diagram Basics	31	(2)
Saw Tooth Example---Analyzing the Behavior of a Part Number	33	(1)
Saw Tooth Assumptions vs. Reality	34	(1)
Analyzing Demand Pattern Variability	35	(4)
Lead Time and Lot Size Guidelines	39	(16)
Using the Economic Order Quantity (EOQ) Formula	41	(4)
Fine-tuning the EOQ	45	(2)
Setting Lot Size Guidelines	47	(2)
Managing Replenishment Lead Times	49	(3)
Determining Lead Time Objectives	52	(3)
Statistics 101 and Demand Variability	55	(12)
Customer Demand Variability	55	(2)
Using Z Scores	57	(5)
How Much Safety Stock Is Enough?	62	(2)
Deciding Which Parts to Put on Kanban	64	(3)
Saw Tooth Exercises	67	(12)
Managing Kanban During Decreasing Demand	67	(2)
Recommend Actions for Adjusting to Decreasing Demand	69	(2)
Applying the Solutions for Decreasing Demand	71	(3)
Other Supply/Demand Issues	74	(1)
The Problem of Early Deliveries	75	(4)
Physical Techniques of Kanban Replenishment Systems	79	(18)
Using Kanban's Manual-Visual Control Techniques	80	(3)
Techniques to Identify the Order Point Inside the Bin	83	(3)
Information on the Kanban Card	86	(1)
Options for Designating Permanent Locations	87	(4)
Kanban Management for Raw Materials	91	(2)
Cautions and Recommendations for Setting the Order Point	93	(4)
Kanban Maintenance	97	(8)
Kanban Adjustment Report and Card Maintenance	97	(4)
Supplier Performance Reports and Stock-out Expedite Tracking Report	101	(1)
Kanban Audits	101	(4)
Kanban Implementation Approach	105	(8)
Roles and Responsibilities in Kanban Implementation	105	(4)
Using a Project Plan for Implementing Kanban	109	(4)
Stabilizing Production	113	(8)
Creating a Hybrid Push/Pull Model---Min/Max Stabilization Process	115	(2)
Calculating Min/Max Levels	117	(4)
Conclusion	121	(4)
What You Have Learned---What You Need to Practice	121	(1)
Next Steps	122	(1)
Final Word on Lean	123	(2)
Index	125	(5)
About the Author	130