Integrating Kanban With Mrpii

by Louis, Raymond S.

• ISBN13: 9781563271823
• ISBN10: 1563271826
• Format: Hardcover
• Copyright: 1997-09-01
• Publisher: Productivity Pr

Summary

If you manage inventory, you probably use MRPII. MRPII has exceptional planning capabilities, but it is riddled with non-value-added activities. Manual kanban is a system designed to control a JIT environment. Compared to MRPII, it lowers inventory and minimizes shortages. But the manual process of recalculating part numbers by hand is time-consuming. This book describes an automated kanban system that integrates MRPII, kanban, bar codes, and a simple version of electronic data interchange into a breakthrough system that substantially lowers inventory and significantly eliminates non-value-adding activities.

Table of Contents

Publisher's Message	xiii	(4)
Preface	xvii	(6)
Acknowledgments	xxiii
CHAPTER 1. Eliminating Replenishment System Waste	1	(14)
Replenishment System Review--Non-Value-Added Activities	2	(10)
Push System Versus Pull System	3	(2)
Manufacturing Resource Planning (MRPII)	5	(4)
Order Point System	9	(1)
Manual Kanban	10	(2)
Automated Kanban System -- Waste Elimination	12	(3)
CHAPTER 2. Replenishment System Basics	15	(28)
MRPII Overview	16	(4)
Master Production Schedule Module	16	(1)
Material Requirements Planning Module	17	(2)
Shop Scheduling Module	19	(1)
Capacity Requirements Planning Module	19	(1)
Order Point System Overview	20	(1)
Manual Kanban System Overview	21	(7)
Internal Move Card	22	(1)
Production Card	22	(3)
Supplier Card	25	(1)
Broadcast	25	(1)
Load-Smoothing and Sequencing	25	(3)
Manual Kanban System--Kanban Calculation	28	(15)
Production Card Calculation for Nonflexible Work Cells	29	(1)
Determining Lead Time for a Nonflexible Work Cell	30	(3)
Nonflexible Work-Cell Production-Card Calculation	33	(1)
Flexible Work-Cell Production-Card Calculation	34	(1)
Internal Move Card Calculation	35	(2)
Supplier Card Calculation	37	(6)
CHAPTER 3. Automated Kanban -- The Automated Flow Technology	43	(24)
Automated Flow Technology	44	(12)
Calculating Kanban Lot Sizes	44	(1)
Creating Purchase Orders and Performing Download Upon Consumption	45	(4)
Creating and Displaying Triggered Manufacturing Orders Upon Consumption	49	(4)
Performing Receipts	53	(1)
Calculating Flexible Work-Cell Staffing	53	(3)
Automated Flow Technology Programming	56	(5)
Kanban Calculation/Simulation Program (KCSP)	56	(1)
KCSP Programming	57	(2)
Cell-Staffing Calculation Programming (CSCP)	59	(1)
MRPII Enhancements	60	(1)
Lead-Time Definitions for the AFT System	61	(3)
Supplier Lead Time	61	(1)
Purchasing Replenishment Lead Time	62	(1)
Manufacturing Lead Time	63	(1)
Manufacturing Replenishment Lead Time	63	(1)
Kanban Lot Size Versus Kanban Order Quantity	64	(1)
Kanban Order Policy Code	64	(1)
Supplier Download Capability	65	(2)
CHAPTER 4. Kanban Prerequisites--WCM Techniques	67	(36)
Objective One: Reduce Manufacturing and Supplier Replenishment Lead Times	68	(3)
Objective Two: Reduce Batch Sizes	71	(1)
Objective Three: Rectify Potential Obstacles That Can Impede Replenishment Performance	71	(1)
Kanban Prerequisites	72	(29)
World Class Manufacturing Conversion Plan	73	(2)
Just-in-Time Education	75	(2)
Total Productive Maintenance (TPM) Program	77	(2)
Quick Changeover Program	79	(2)
Zero Quality Control	81	(2)
Visual Workplace	83	(1)
Focused Factory/Work Cells	84	(2)
Backflushing/Deduct Point Capability	86	(2)
Stockroom Elimination	88	(3)
Performance Measurement	91	(1)
Container Selection	91	(4)
Supplier Performance Rating and Supplier Contracts	95	(5)
Data Integrity	100	(1)
Prerequisites Completed	101	(2)
CHAPTER 5. Implementing Kanban	103	(14)
OEM Internal Kanban Implementation	103	(9)
Begin Implementing Kanban at Final Assembly	104	(1)
Impact of Nonlinear Demand Patterns	104	(2)
Selecting Specific Part Numbers for Kanban	106	(2)
How to Handle Common Components	108	(1)
Perform Cycle-Counting	109	(1)
Applying Safety Stock	109	(1)
Track the Inventory Levels	110	(1)
OEM Kanban Procedures and Training	111	(1)
Key Processes to Monitor During the OEM's Internal Implementation	112	(1)
Implementing Kanban with Your Supplier Base	112	(3)
Supplier Performance Ratings	113	(1)
Suppliers That Should Not Be Placed on Kanban	113	(1)
Selecting Specific Part Numbers for Kanban	113	(1)
Supplier's Involvement in the Selection of Containers	114	(1)
OEM as a Resource	114	(1)
Key Processes to Monitor During the Supplier Implementation	115	(1)
Speed of Overall Kanban Implementation	115	(2)
CHAPTER 6. Kanban and MRPII System Integration	117	(22)
AFT Key Computer Fields and Their Functions	117	(17)
Key Files Required by the AFT System	134	(3)
Simplified Version of EDI	136	(1)
Before Programming the AFT System	137	(2)
CHAPTER 7. AFT Calculations for Determining Kanban Lot Sizes and Staffing Levels	139	(22)
Determining Kanban Lot Sizes with AFT	140	(19)
Gross Requirements	140	(1)
Kanban Lot-Size Formula	141	(1)
Formula Modifier	141	(1)
Kanban Lot-Size Calculation Steps	142	(6)
KCSP Simulation Routine	148	(9)
Formula Modifier Setting	157	(2)
Determining Flexible Work-Cell Staffing Levels by Using CSCP	159	(2)
CHAPTER 8. Perpetuation of the Automated Kanban System	161	(24)
Supplier One-Line-per-Item MRP Report	162	(5)
Gross Requirements Report	164	(1)
Net Requirements Report	164	(3)
Planned Order Release Report	167	(1)
Supplier Kanban Trigger Report	167	(3)
Manufacturing Queue Screen	170	(3)
Purchasing and Manufacturing Shortage Reports	173	(2)
Flexible Work-Cell Staffing Report	175	(1)
Add/Subtract Multiple Container Report	176	(1)
Adjust Kanban Report for Single Container	177	(1)
Trigger Kanban Report for Dual/Triple-Container Option	177	(3)
Adjust Kanban Report for Dual/Triple-Container Option	180	(1)
Purchasing Kanban Due Report	180	(2)
Supplier Performance Rating Report	182	(3)
CHAPTER 9. Key Topics of the Automated Kanban System	185	(14)
Managing the Transportation Cost	185	(1)
Mistake-Proof the AFT Triggering Capability	186	(1)
Non-Work-Cell Kanban Items	187	(1)
Reacting to Customer Demand Versus Producing to a Frozen Schedule	188	(1)
Standard Product Finished Goods/Allocation Methodology	188	(1)
Nonlinear Customer Demand	189	(1)
Imbalance of Inventory	190	(1)
High Degree of Commonality	190	(1)
Broadcast Application	191	(1)
Short Receipt Policy	192	(1)
Frequency of Kanban Recalculation	193	(1)
Impact of Not Lot-Sizing MRP	193	(1)
Automated Kanban System Design Process--General Guideline	194	(5)
CHAPTER 10. Three Examples of AFT Implementation	199	(14)
North Star	199	(6)
Precision Tape Backup	205	(4)
Medical Monitoring	209	(3)
Conclusion	212	(1)
About the Author	213	(2)
Index	215