Pull down production in the most popular multiple

2022-08-01
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Pull down production in a variety of manufacturing environments

needless to say, lean thinking has brought great benefits to enterprises. As we all know, ERP brings a high degree of information and integration to enterprises. At the same time, it also brings convenience for enterprises to deal with changeable and complex manufacturing environment. For example, MTS, MTO, ATO and ETO. This paper focuses on how to change from batch production for equipment manufacturers of recycled plastic granulator to lean production of continuous production process, implement Kanban pull system, and implement electronic Kanban system well integrated with ERP under the four environments of ERP

the production and inventory strategy of an enterprise determines the focus of production management and inventory management. It plays an important role in the competitive lead time and effective inventory control of enterprises. Enterprises should rapidly change their production inventory strategy according to the changes of market competition environment. This requires enterprises to have a high degree of flexibility in planning, production layout, inventory and production preparation

I. for the inventory environment

before receiving the customer's order, the product has been warehoused and is waiting for shipment. Use the MPS master production plan or SOP sales forecast of ERP to drive the finished product plan, MRP mass production and queuing supply to organize production

under lean production, the production is organized by means of Kanban pull plan and continuous flow of single piece. It features stable logistics

this figure is a typical Toyota pull production. The customer sends a Kanban in the form of electronic data, fax, empty box and cardboard. The products are pulled from the finished product supermarket and shipped to the customer for delivery. During this period, the internal Kanban returns to the factory to supplement the goods of the finished product supermarket. The supermarket is based on intuition. Each kind of finished product has code and batch number and strict first in first out management. Perhaps, your company directly targets a large number of wholesalers, whose sales order frequency, quantity and product mix change greatly, and your business model is to deal with customer orders almost immediately. Therefore, there must be a buffered finished product supermarket

II. Order oriented assembly environment

it means that the sub assemblies have been completed and they are assembled into the final product after receiving the order. Key components can be planned and stored in the warehouse to wait for customer orders. The master production plan drives sub assembly or critical component planning

this figure is a typical Dell pull production. This kind of Kanban mode is becoming more and more popular. Since there is virtually no finished product inventory (except for products waiting to be shipped), company resources can be effectively managed. The premise is that the replenishment cycle of manufacturing is less than the delivery time of the order. Dell uses this method on the Internet to directly connect with customer orders. For example, the daily delivery volume of orders is not uniform, but in production, the average daily output can be used to level the production line

III. order oriented production environment

it completes product manufacturing after receiving customer orders. In order to shorten the delivery time, it is often necessary to plan the sub items with a long lead time before accepting the order

there are potential difficulties in handling extremely irregular orders and implementing the pull plan. Implement a visual and electronic dynamic Kanban system, automatically adjust the number of Kanban and Kanban loop to adjust the buffer inventory, so as to effectively meet the irregular order demand. Although this requires an increase or decrease in the actual number of containers, and the buffer may increase, it is also more effective than you try to plan or predict. Because the prediction driven MRP will magnify the problems existing in the supply chain

in fact, in the process of process transfer or transportation of parts, it is essential to understand the productivity of customers, timely adjust their own takt, design their own flexible production lines and combine them with suppliers to form a strategic alliance

the picture data comes from the fourth shift Kanban system

IV. order oriented design environment

it carries out unique design or customization according to the customer's specifications. Customer orders typically require a unique set of part numbers, bill of materials, and routing

to sum up, the essential difference between the four processes is how to set up a parts supermarket. Usually, we set a small internal buffer warehouse between the final assembly line and the upstream supplier. Internal Kanban is used to handle internal replenishment goods. As the replenishment time becomes shorter and shorter, the buffer capacity of the supermarket will continue to decrease. Therefore, another key element to maintain a small supermarket is the minimum preparation time (smed)

some traditional enterprises that continuously, Bi directionally and proportionally control the flow or pressure of the hydraulic system, the old equipment layout and large-scale mass production equipment do need mass production. It is really difficult to turn to pull lean production. However, we can first set up a parts supermarket between each process, so that we can quickly supplement supplies to operations that consume parts such as data editing. The longer-term solution is to reduce the equipment for mass production and gradually shorten the supply time to form a continuous production process

external Kanban is connected with suppliers to generate electronic Kanban, which is integrated with ERP procurement and a/P modules to reduce the loss of kanban. Streamline Kanban, purchase and a/P processes

lean enterprises may think that the manual Kanban system is simpler. The reason is that it can be quickly

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