![]() They are the most well know Lean material management tool, but by no means the only one. Kanban Kanban cards like these trigger replenishment of materials. This means that production at the upstream process is “pulled” by the consumption of parts at the downstream process. In these situations a pull approach can be used. three-shift machining) it can also be very difficult to achieve flow. Where processes have different hours of operation (e.g. For example, a process where it is necessary to run a batch of product such as heat treatment or plating or where set up times are too long to permit a batch size of one unit. This controls the work in progress and ensures consistent, fast lead time for all products flowing between the two processes. Once the lane is full the upstream process needs to stop. A FIFO lane has space for a limited amount of product, usually no more than a few hours of production. Failing that, a “First in First Out” (FIFO) lane can be used to control work between processes. Each process hands the product on to the next process without work in progress or delay between processes. The ideal is “one-piece flow” such as on an assembly line or production “cell”. This means that individual products flow from process to process in sequence. In a lean process, we aim to achieve “flow”. If you are one of the many companies which cannot get accurate forecasts from customers, then the ERP approach will be ineffective. This approach relies on customer forecasts being accurate. This is called a “push” system since materials and production are “pushed” through the production process in anticipation of future customer demand. ![]() In this approach, the business enters a forecast for expected customer requirements in the future. I call this automating the chaos! There are very many systems available, but most offer an enterprise resource planning or ERP approach. The first response many companies adopt to overcome problems with material shortages and late deliveries are to look for a software solution. READ ON TIME IN FULL TO FIND LEAN SOLUTIONS FOR YOUR SUPPLY CHAIN The Difference Between Push, Pull and Flow It is at this point you will probably get introduced to some new concepts for managing the flow of production jobs and materials. From this, you can develop your future state map. A value stream map will show the process steps and, critically, the information flows that trigger the movement of materials and production jobs from one process to the next. ERP systems also fail to offer solutions to many companies. Instead, they often rely on cumbersome and ineffective spreadsheets. Many companies know about Kanban and pull systems, but few seem confident to use them. The cause is the inability to get materials to the right place at the right time and in the right quantity. However, often despite these efforts manufacturers still suffer downtime, poor productivity and missed deliveries. Over the years many manufacturers have adopted Lean tools focused on improving the efficiency of production processes. ![]() Theme song by Gabbie Watts.Tim McLean’s book On Time In Full Provides Detailed Solutions to Your Material Management Problems The Keys to Successful Lean Material Management Instagram Carnival of Tears 2: Into the Light by Matt Oakly Join our Facebook group Sometimes Groups are Better Follow her on Instagram and design by Katherine Ross They first discuss escalator accidents, then go on a tangent about Vince Neil and Casey tells his first exposure to cannibalism. This incident reminds Christin of the movie they talked about last week, Dawn of the Dead (1978). In this part 2 episode Chris and Christin's brother Casey gather around Christin as she tells them the disturbing true crime story of murder of Tim Mclean on a Greyhound bus. ![]()
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