Integrating
Kanban with MRP II (p): Automating a Pull System for Enhanced JIT Inventory
Management
Author: Raymond S. Louis
Product Code: 3233
ISBN: 1-56327-323-3
Publisher: Productivity Press
Published: 2005
Pages: 212
Illustrated: Yes
Pages Description: illustrations/tables/charts/index
Price: US $38.00
If you manage inventory, you probably use MRPII, a system based on a
push method that embraces work and purchase order execution. MRPII helps
you plan and integrate data relevant to your entire organization. But,
when you have shifts in demand, you have to: 1) Realign and cancel hundreds
of open manufacturing and purchase orders, and then 2) issue new orders.
Another system, kanban, is designed specifically to replenish inventory
in just-in-time manufacturing. As consumption occurs, the kanban manual
system triggers replenishment signals to the source of supply, so that
both production and the supplier are constantly reacting to actual consumption.
Compared to MRPII, kanban lowers inventory and minimizes shortages.
But the manual process of recalculating every part number by hand, and
triggering replenishment by faxing or calling suppliers, is time consuming
and non-value-adding.
Automating kanban by blending the planning strength
of MRPII with manual kanban pull methods enhances your flexibility and
competitive position.
MRP's forward projection capability is used to:
recalculate kanban lot size.
perform a simulation to protect against non-linear demand.
inform production areas and suppliers of the anticipated demand levels
for resource planning.
calculate staffing requirements for flexible work cells.
This system:
Automatically recalculates and triggers replenishment.
Integrates suppliers into the manufacturing loop.
Uses bar codes to enhance speed and accuracy of the receipt process.
Before moving in this direction, preparatory work is required. Work
cells should be constructed with material located at the point of use.
Container options and transportation methods need to be selected, kanban
lot size calculations, and work cell staffing modules to develop. This
book will help you deal with these and other topics. You will be able
to take advantage of the author's expertise in the design, implementation
and evaluation of these systems.
Table of Contents
Eliminate Replenishment System Waste
Replenishment System Basics
Automated Kanban -- The Automated Flow Technology
Kanban Prerequisites -- WCM Techniques
Implementing Kanban
Kanban and MRPII System Integration
AFT Calculations for Determining Kanban Lot Sizes and Staffing Levels
Perpetuation of the Automated Kanban
Key Topics of the Automated Kanban System
Three examples of AFT Implementation
Reviews
Review By: Khamis Refai, Bell Industries - April 5,
2005
"Bell Industries, as a supplier, went on the automated kanban system
initiated by Raymond Lewis. We found it beneficial from our perspective
as it (1) gave us projected visibility to procure our supplies, (2)
freed our personnel from manual phone order process, (3) provided consistent
releases enhancing our inventory turns, and (4) increased our business
levels through the OEM's consolidation of suppliers."
Review
By: Robert Gelber, Coherent Auburn Group - April 5, 2005
"The automated kanban system that Raymond Lewis designed and implemented
at Coherent Auburn Group has resulted in significant cost savings."
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