Replenishment buffer management

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Replenishment buffer management

  1. 1. MANAGING SYSTEMATIC PRODUCTION “ Working managers, not managed workers,” is the way of the future UNDESTANDING DRUM – BUFFER - ROPE
  2. 2. DRUM: THE WEAKEST LINK ( PERIOD ) THE SHOP CAN ONLY GET SO MANY LABOR HOURS THROUGH THE PAINT BOOTH IN A DAY OR WEEK. WE TRY TO STUFF A MARSHMELLOW IN A PIGGY BANK EVERY DAY ! DON’T WE? SAY YOUR PAINT BOOTH IS YOUR PIGGY BANK / DRUM THIS IS CALLED THE DRUM: THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.
  3. 3. <ul><li>WE THE COMPANY WILL NOW LEARN TO COORDINATE EVERY THING ELSE AROUND THIS FIXED PLACE. </li></ul><ul><li>WE DO SO BY FIXING OUR SYSTEMS “NAIL THEM DOWN” IN ONE PLACE OF MAXIMUM LEVERAGE AT THE CONSTRAINT. </li></ul>
  4. 4. FIXING OUR SYSTEMS “NAIL THEM DOWN” What is gate control? Understanding Replenishment Buffer What is the drum buffer? Understanding the drum What is the shipping gate? How do we Rope / tie it all together GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER
  5. 5. <ul><li>WHAT IS GATE CONTROL ? </li></ul><ul><li>Gate control allows Constant Work-In-Process, and designates a control strategy that limits the total number of labor hours allowed into the system at the same time. </li></ul><ul><li>The hours are released as they are processed at the consumption rate of the beat of the drum until they wind up in the last buffer as finished goods. </li></ul>LABOR HRS. ARE RELEASED FROM THE REPLENISHMENT BUFFER GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER
  6. 6. <ul><li>Understanding Replenishment Buffer </li></ul><ul><li>Replenishment Buffer management is a control mechanism. </li></ul><ul><li>The idea behind it can be summarized in the following steps. </li></ul><ul><li>Use the Replenishment Buffer to release labor hours as they are processed at the consumption rate of the drum. </li></ul><ul><li>AFTER </li></ul><ul><li>1 Disassemble the vehicle , identified parts and labor necessary to repair the vehicle. </li></ul><ul><li>2 Verified parts price and availability, Order parts and place vehicle into the staging area. </li></ul><ul><li>3 Verified parts by mirror match parts, </li></ul><ul><li>4 kit repair for production . </li></ul>
  7. 7. <ul><li>WHAT IS THE DRUM BUFFER ? </li></ul><ul><li>ALL OF THE WORK IN PROCESS BETWEEN THE GATE AND THE DRUM CONSTITUTES THE DRUM BUFFER. </li></ul><ul><li>ALL OF THE WIP PRIOR TO COMPLETION CONSTITUTES THE SHIPPING BUFFER. </li></ul>GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER
  8. 8. <ul><li>UNDESTANDING DRUM </li></ul><ul><li>DRUM: THE WEAKEST LINK IS THE RATE LIMITING STEP. </li></ul><ul><li>THE DRUM BEATS OUT THE PRODUCTION RATE FOR THE WHOLE SYSTEM. </li></ul>GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER
  9. 9. <ul><li>WHAT IS THE SHIPPING GATE ? </li></ul><ul><li>SHIPPING GATE IS DISCRIBED AS FOLLOWED: </li></ul><ul><li>REASSEMBLY OF THE VEHICLE </li></ul><ul><li>DETAIL </li></ul><ul><li>QUALITY INSPECTION OF FINAL PRODUCT </li></ul>GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER
  10. 10. SYSTEMATIC PRODUCTION VIEW Replenishment buffer management is key to systemic warehousing and distribution GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER REPLENISHMENT BUFFER STATE FARM AIG GEICO
  11. 11. SYSTEMATIC PRODUCTION VIEW REPAIR WORK COMES IN TO YOUR SHOP WE WILL CALL THIS YOUR PIPE LINE OR FUNNEL STATE FARM AIG GEICO
  12. 12. <ul><li>Disassemble the vehicle , identified parts and labor necessary to repair the vehicle. </li></ul><ul><li>Verified parts price and availability, Order parts and place vehicle into the staging area REPLENISHMENT BUFFER </li></ul>3 Verified parts by mirror match parts, 4 kit repair for production .
  13. 13. Gate control allows Constant Work-In-Process , and designates a control strategy that limits the total number of labor hours allowed into the system at the same time. The hours are released as they are processed at the consumption rate of the beat of the drum until they wind up in the last buffer as finished goods ALL OF THE WIP BETWEEN THE GATE AND THE DRUM CONSTITUTES THE DRUM BUFFER.
  14. 14. DRUM: THE WEAKEST LINK IS THE RATE LIMITING STEP. THE DRUM BEATS OUT THE PRODUCTION RATE FOR THE WHOLE SYSTEM . IN THE BODY SHOP THE DRUM IS THE PAINT BOOTH. WE ARE LIMITED TO HOW MANY UNITS OR HRS CYCLE THOUGH IT A DAY OR WEEK. THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.
  15. 15. SHIPPING BUFFER IS DISCRIBED AS FOLLOWED: 1 REASAMBLY OF THE VEHICLE 2 DETAIL 3 QUALITY INSPECTION OF FINAL PRODUCT SHIPPING BUFFER
  16. 16. Thank you for giving me the opportunity to train your company in understanding Systematic production. Now that you understand the process we can now find your capacity and work on improving your through- put and reduce cycle time. PRESENTED BY. RANDY S FERRESE SR 824 BLUEBIRD CIRCLE MAYS LANDING ,NJ 08330 [email_address] 609 553 4244

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