Integrating Kanban with MRP II: Automating a Pull System for Enhanced JIT Inventory Management

by Louis, Raymond S.

• ISBN13: 9781563273230
• ISBN10: 1563273233
• Format: Paperback
• Copyright: 2005-02-28
• Publisher: Productivity Pr

Summary

This book describes an automated kanban system that integrates MRPII, kanban bar codes, and a simple version of electronic data interchange into a powerful system that substantially lowers inventory levels and significantly eliminates non-value-adding actions.

Table of Contents

Publisher's Message	p. xiii
Preface	p. xvii
Acknowledgments	p. xxiii
Eliminating Replenishment System Waste	p. 1
Replenishment System Review-Non-Value-Added Activities	p. 2
Push System Versus Pull System	p. 3
Manufacturing Resource Planning (MRPII)	p. 5
Order Point System	p. 9
Manual Kanban	p. 10
Automated Kanban System-Waste Elimination	p. 12
Replenishment System Basics	p. 15
MRPII Overview	p. 16
Master Production Schedule Module	p. 16
Material Requirements Planning Module	p. 17
Shop Scheduling Module	p. 19
Capacity Requirements Planning Module	p. 19
Order Point System Overview	p. 20
Manual Kanban System Overview	p. 21
Internal Move Card	p. 22
Production Card	p. 22
Supplier Card	p. 25
Broadcast	p. 25
Load-Smoothing and Sequencing	p. 25
Manual Kanban System-Kanban Calculation	p. 28
Production Card Calculation for Nonflexible Work Cells	p. 29
Determining Lead Time for a Nonflexible Work Cell	p. 30
Nonflexible Work-Cell Production-Card Calculation	p. 33
Flexible Work-Cell Production-Card Calculation	p. 34
Internal Move Card Calculation	p. 35
Supplier Card Calculation	p. 37
Automated Kanban-The Automated Flow Technology	p. 43
Automated Flow Technology	p. 44
Calculating Kanban Lot Sizes	p. 44
Creating Purchase Orders and Performing Download Upon Consumption	p. 45
Creating and Displaying Triggered Manufacturing Orders Upon Consumption	p. 49
Performing Receipts	p. 53
Calculating Flexible Work-Cell Staffing	p. 53
Automated Flow Technology Programming	p. 56
Kanban Calculation/Simulation Program (KCSP)	p. 56
KCSP Programming	p. 57
Cell-Staffing Calculation Programming (CSCP)	p. 59
MRPII Enhancements	p. 60
Lead-Time Definitions for the AFT System	p. 61
Supplier Lead Time	p. 61
Purchasing Replenishment Lead Time	p. 62
Manufacturing Lead Time	p. 63
Manufacturing Replenishment Lead Time	p. 63
Kanban Lot Size Versus Kanban Order Quantity	p. 64
Kanban Order Policy Code	p. 64
Supplier Download Capability	p. 65
Kanban Prerequisites-WCM Techniques	p. 67
Reduce Manufacturing and Supplier Replenishment Lead Times	p. 68
Reduce Batch Sizes	p. 71
Rectify Potential Obstacles That Can Impede Replenishment Performance	p. 71
Kanban Prerequisites	p. 72
World Class Manufacturing Conversion Plan	p. 73
Just-in-Time Education	p. 75
Total Productive Maintenance (TPM) Program	p. 77
Quick Changeover Program	p. 79
Zero Quality Control	p. 81
Visual Workplace	p. 83
Focused Factory/Work Cells	p. 84
Backflushing/Deduct Point Capability	p. 86
Stockroom Elimination	p. 88
Performance Measurement	p. 91
Container Selection	p. 91
Supplier Performance Rating and Supplier Contracts	p. 95
Data Integrity	p. 100
Prerequisites Completed	p. 101
Implementing Kanban	p. 103
OEM Internal Kanban Implementation	p. 103
Begin Implementing Kanban at Final Assembly	p. 104
Impact of Nonlinear Demand Patterns	p. 104
Selecting Specific Part Numbers for Kanban	p. 106
How to Handle Common Components	p. 108
Perform Cycle-Counting	p. 109
Applying Safety Stock	p. 109
Track the Inventory Levels	p. 110
OEM Kanban Procedures and Training	p. 111
Key Processes to Monitor During the OEM's Internal Implementation	p. 112
Implementing Kanban with Your Supplier Base	p. 112
Supplier Performance Ratings	p. 113
Suppliers That Should Not Be Placed on Kanban	p. 113
Selecting Specific Part Numbers for Kanban	p. 113
Supplier's Involvement in the Selection of Containers	p. 114
OEM as a Resource	p. 114
Key Processes to Monitor During the Supplier Implementation	p. 115
Speed of Overall Kanban Implementation	p. 115
Kanban and MRPII System Integration	p. 117
AFT Key Computer Fields and Their Functions	p. 117
Key Files Required by the AFT System	p. 134
Simplified Version of EDI	p. 136
Before Programming the AFT System	p. 137
AFT Calculations for Determining Kanban Lot Sizes and Staffing Levels	p. 139
Determining Kanban Lot Sizes with AFT	p. 140
Gross Requirements	p. 140
Kanban Lot-Size Formula	p. 141
Formula Modifier	p. 141
Kanban Lot-Size Calculation Steps	p. 142
KCSP Simulation Routine	p. 148
Formula Modifier Setting	p. 157
Determining Flexible Work-Cell Staffing Levels by Using CSCP	p. 159
Perpetuation of the Automated Kanban System	p. 161
Supplier One-Line-per-Item MRP Report	p. 162
Gross Requirements Report	p. 164
Net Requirements Report	p. 164
Planned Order Release Report	p. 167
Supplier Kanban Trigger Report	p. 167
Manufacturing Queue Screen	p. 170
Purchasing and Manufacturing Shortage Reports	p. 173
Flexible Work-Cell Staffing Reprt	p. 175
Add/Subtract Multiple Container Report	p. 176
Adjust Kanban Report for Single Container	p. 177
Trigger Kanban Report for Dual/Triple-Container Option	p. 177
Adjust Kanban Report for Dual/Triple-Container Option	p. 180
Purchasing Kanban Due Report	p. 180
Supplier Performance Rating Report	p. 182
Key Topics of the Automated Kanban System	p. 185
Managing the Transportation Cost	p. 185
Mistake-Proof the AFT Triggering Capability	p. 186
Non-Work-Cell Kanban Items	p. 187
Reacting to Customer Demand Versus Producing to a Frozen Schedule	p. 188
Standard Product Finished Goods/Allocation Methodology	p. 188
Nonlinear Customer Demand	p. 189
Imbalance of Inventory	p. 190
High Degree of Commonality	p. 190
Broadcast Application	p. 191
Short Receipt Policy	p. 192
Frequency of Kanban Recalculation	p. 193
Impact of Not Lot-Sizing MRP	p. 193
Automated Kanban System Design Process-General Guideline	p. 194
Three Examples of AFT Implementation	p. 199
North Star	p. 199
Precision Tape Backup	p. 205
Medical Monitoring	p. 209
Conclusion	p. 212
Index	p. 213
About the Author	p. 219
Table of Contents provided by Ingram. All Rights Reserved.