RB Erpleanmoduleoverview 120507110109 Phpapp02

RB-ERP Lean Module
1
Agenda
Background
Lean / Kanban APICS Definitions and Concepts
Example
Overview of RB-ERP Lean
Walkthrough of RB-ERP Lean
Questions and Answers
2
Lean Manufacturing Definition
Lean embodies a set of principles and practices that reduce cost through the
relentless removal of waste and through the simplification of all manufacturing
and support processes.
Lean is a philosophy of production that emphasizes the minimization of the

amount of all the resources (including time) used in the various activities of the
enterprise
Lean involves identifying and eliminating non-value-adding activities in design,

production, supply chain management, and dealing with the customers.
Lean producers employ teams of multi-skilled workers at all levels of the

organization and use highly flexible, increasingly automated machines to produce
volumes of products in potentially enormous variety.
- APICS
3
Kanban Definition
The Japanese word Kanban, loosely translated, means card, billboard,
or sign, but other signaling devices such as colored golf balls have also
been used. The term is often used synonymously for the specific
scheduling system developed and used by the Toyota Corporation in
Japan.
Kanban is a method of Just-in-Time production that uses standard

containers or lot sizes with a single card attached to each.
It is a pull system in which work centers signal with a card or other

device that they wish to withdraw parts from feeding operations or
suppliers.
APICS
4
Pull as an Integral Part of
Lean Manufacturing
5
COMMON TOOLS OF LEAN
VALUE STREAM MAPPING QUALITY AT SOURCE

5Ss POINT OF USE STORAGE
VISUAL QUICK CHANGEOVER (SMED)
PLANT LAYOUT CELLULAR/ GROUP TECH.
STANDARDIZED WORK
TOTAL PREVENTATIVE
BATCH REDUCTION MAINTENANCE
TEAMS/CROSS TRAINING DEMAND PULL/ KANBAN
SIX SIGMA
6
Push vs. Pull
Push Produce to forecast of Pull Produce ONLY the

anticipated demand necessary units in the
Excessive inventory (stock necessary quantities at the
out of whats needed)
necessary times
Large batches
Simple manage by eye
Inability to keep pace with
real-time orders Responsive to minor changes
Inefficient ops high costs Effective at continuous
Emergency changeover inventory reduction
Product teardowns
Expediting Hot list
7
Kanban Example
8
Kanban Example BOM
SP-4 Manufactured
C-40 Manufactured
C-400 Purchased
Inventoried at 2 Locations
9
Kanban Circuits
Vendor
Finished parts
inventory
Receive Receive
Production Production
SP-4
Raw material
inventory
Demand
Customer
Procurement Kanban Circuit
Transfer Kanban Circuit
Production Kanban Circuit

10
Kanban flow
Supplier
Receive for C-400
Initiate Initiate Receive Initiate Receive Initiate

Procurement Transfer for C-40 Production for SP-4 Production
Receive C-400 C-40 SP-4
C-400
C-400
Receive Receive
Kanban Kanban
Bin: PICK Bin: FLOOR Bin: FLOOR Bin: END
Ship 10
Location KB Location 01 END
Incoming
Empty container Customer Order
Kanban Quantities = 10 10 SP-4
Full container 11
RB-ERP Approach
12
RB-ERP Traditional Replenishment
Demand Pull Demand Pull
Cust Order Shop Order

N/C Lines N/C Comps
Push Push Push
MPS Planned MRP Planned Inventory

Orders Orders Reorder
Point
Order Review
Shop Order Req/Purchase

Order
13
RB-ERP Lean Development
Generate/Manage Card Issuance

Simple Kanban Transaction Entry (Bar Code Scan)
Trigger Purchase Order/Release, Notification and
Receipt
Trigger Inventory Transfer
Trigger Production Receipt & Backflush
History of Kanban Activity with Cycle Time
Tracking
15
RB-ERP Lean Module
Database Schema
Item Location Key = Item/Location
Key = Item/Location/Destination
Kanban Circuit
Kanban Circuit Contains default information for
Kanban Circuit Kanbans in circuit, Number of
Kanbans in circuit, etc.
Key = Kanban ID
Kanban Alternate Key = Item/Location/Destination
Kanban
Kanban Contains Type of Kanban, Kanban,
Quantity, etc.
Key = Kanban ID / Count Usage

Kanban History Contains History of Kanban Usage
Kanban History
Kanban History including date/time stamps
16
Kanban Destination Table
17
Kanban Item/Location Flag
18
Kanban Circuit Definition
19
New Kanban Circuit
and Kanban Deployment
20
Kanban
21
RB-ERP Lean Module
Kanban Generation and Deployment
Receive Receive Receive

Transfer Production Procurement
Kanban Kanban Kanban
Inventory Mfg Receipt PO Receipt

Transfer & Backflush
22
Single Entry/Scan of Kanban
Kanbans May Be Both

Initiated and Received
23
Receive Transfer Kanban
Yes
No
24
Receive Production Kanban
Yes
No
25
Move to by Step,
Then Receive Production Kanban
Yes
No
Update Kanban
Valid Data? Initiated?
Yes Yes Current Op
No No
Initiate Kanban Create Move
Signal Error
History Record
Create Initiate
History Record
26
Initiate Procurement Kanban
Option:
Create/Release PO
Create New PO
Add PO Line
Option:
Cut Release
Blanket Release
Option:
Add Line to PO
Add Line
Add History Record
27
(Optional)
Receive Procurement Kanban
Yes
No Yes Perform PO Update Kanban

Initiated?
Receipt History Record
Yes
No
Signal Error &

No
Disallow
28
RB-ERP Kanban Data Setup
RB-ERP Lean Module
Kanban Generation and Deployment
Receive Receive Receive

Transfer Production Procurement
Kanban Kanban Kanban
Inventory Mfg Receipt PO Receipt

Transfer & Back-flush
RB-ERP Kanban Walkthrough
RB-ERP Lean Development
Questions and Answers

RB-ERP Lean Module
33

RB Erpleanmoduleoverview 120507110109 Phpapp02

Uploaded by

Copyright:

Available Formats

RB Erpleanmoduleoverview 120507110109 Phpapp02

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

RB Erpleanmoduleoverview 120507110109 Phpapp02

Uploaded by

Copyright:

Available Formats

RB-ERP Lean Module

Lean is a philosophy of production that emphasizes the minimization of the

Lean involves identifying and eliminating non-value-adding activities in design,

Lean producers employ teams of multi-skilled workers at all levels of the

Kanban is a method of Just-in-Time production that uses standard

It is a pull system in which work centers signal with a card or other

VALUE STREAM MAPPING QUALITY AT SOURCE

Push Produce to forecast of Pull Produce ONLY the

Transfer Kanban Circuit

Production Kanban Circuit

Receive for C-400

Initiate Initiate Receive Initiate Receive Initiate

Bin: PICK Bin: FLOOR Bin: FLOOR Bin: END

Cust Order Shop Order

MPS Planned MRP Planned Inventory

Shop Order Req/Purchase

Generate/Manage Card Issuance

Key = Kanban ID / Count Usage

Kanban Generation and Deployment

Receive Receive Receive

Inventory Mfg Receipt PO Receipt

Kanbans May Be Both

Add History Record

No Yes Perform PO Update Kanban

Signal Error &

Kanban Generation and Deployment

Receive Receive Receive

Inventory Mfg Receipt PO Receipt

Questions and Answers

You might also like