Cimorelli Kanban for the Supply Chain

Fundamental Practices for Manufacturing Management, Second Edition
2. Auflage 2013
ISBN: 978-1-4822-0926-6
Verlag: Taylor & Francis
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 137 Seiten

Following in the footsteps of its popular predecessor, the second edition of this workbook explains how to apply kanban replenishment systems to improve material flow. Kanban for the Supply Chain: Fundamental Practices for Manufacturing Management, Second Edition provides readers with a detailed roadmap for achieving a successful and sustainable kanban implementation.

Detailing the steps required for each stage of the manufacturing and supply chain management process, this updated edition focuses on creating an environment for success. It addresses internal mechanisms, including leveling production schedules, as well as external elements, such as conducting a thorough analysis of customer demand. Numerous techniques are presented for setting up kanban that consider a wide array of material types, dimensions, and storage media. This edition presents a wealth of new tools and techniques useful across the broad spectrum of manufacturing environments, including:

- A statistical data cleansing technique to remove questionable or irrelevant data from kanban calculations

- Correlation analysis based on simple Excel techniques to guide the decisions around which part numbers "qualify" for kanban

- An alternative "stair-step analysis" approach for those who are unable to generate correlation data and prefer to use more readily available monthly demand history

- An approach to analyze supplier performance data vs. lead time and lot size expectations, with risk mitigation strategies for poor performing suppliers

This book is for those who are ready to stop thinking about a conversion from materials requirements planning push techniques to kanban pull techniques and want to make it happen now. Stephen Cimorelli provides actionable advice for installing fundamental kanban concepts that can immediately help you increase manufacturing productivity and profitability. The book includes team-based exercises that reinforce key principles as well as a CD with helpful outlines, charts, figures, and diagrams.

Autoren/Hrsg.

Cimorelli, Stephen

Fachgebiete

• Wirtschaftswissenschaften Betriebswirtschaft Bereichsspezifisches Management Einkauf, Logistik, Supply-Chain-Management
• Wirtschaftswissenschaften Betriebswirtschaft Bereichsspezifisches Management Produktionsmanagement, Qualitätskontrolle
• Wirtschaftswissenschaften Wirtschaftssektoren & Branchen Fertigungsindustrie

Inhaltsverzeichnis

Overview of Kanban in a Lean Environment
What Kanban Does
Definitions: Building a Common Language
Building a Lean Environment
Takt Time
Backflushing
JIT Preparation for Kanban
Begin with 5S

Supply Chain Management Principles
Defining the Supply Chain
What Is Supply Chain Management (SCM)?

Applying the ABC Classification Applying ABC Classification Step-by-Step

The Sawtooth Diagram: Analyzing Inventory Behavior
Sawtooth Diagram Basics
Sawtooth Example: Analyzing the Behavior of a Part Number
Sawtooth Assumptions versus Reality
Analyzing Demand Pattern Variability
Potential Solutions for Covering Potential Stockouts

Lead Time and Lot Size Guidelines
Using the EOQ Formula
Fine-Tuning the EOQ
Establishing Carrying Cost
Setting Lot Size Guidelines
Managing Replenishment Lead Times
Determining Lead Time Objectives

Statistical Analysis 101 and Demand Variability
Customer Demand Variability
Using Z Scores
Recommended Formula
Optimizing Inventory for On-Time Delivery: The Case for Data Cleansing
How Much Safety Stock Is Enough?
Deciding Which Parts to Put on Kanban
Using Correlation Analysis to Guide Kanban Candidate Selection
A Simplified "Stair-Step" Approach

Sawtooth Exercises
Managing Kanban during Decreasing Demand
Recommend Actions for Adjusting to Decreasing Demand
Applying the Solution for Decreasing Demand
Further Lot Size Reduction Is Possible Using a Multicard Approach
Other Supply/Demand Issues
The Problem of Early Deliveries
Two Potential Actions for Early Delivery
The Problem of Late Deliveries

Physical Techniques of Kanban Replenishment Systems
Using Kanban’s Manual–Visual Control Techniques
Painted Squares on the Floor
Technique for Storing Single Card Parts
Technique for Storing Multicard Parts
Techniques to Identify the Order Point Inside the Bin
Information on the Kanban Card
Handling the Kanban Card
Options for Designating Permanent Locations
Kanban Management for Raw Materials
Challenges and Recommendations for Managing Raw Material
Employing a Ledger System for Managing Raw Materials
Cautions and Recommendations for Setting the Order Point

Kanban Maintenance
Kanban Adjustment Report and Card Maintenance
Supplier Performance Reports and Stockout/Expedite Tracking Report
Stockout and Expedite Tracking
Supplier Performance
Kanban Audits

Kanban Implementation
Roles and Responsibilities in Kanban Implementation
Using a Project Plan for Implementing Kanban

Stabilizing Production
Creating a Hybrid Push/Pull Model: Min/Max Stabilization Process
Calculating Min/Max Levels

Conclusion
What You Have Learned—What You Need to Practice
Next Steps
Final Word on Lean

Index