Supermarket delivery system

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Description of a supermarket pull system that utilizes kanban cards and a specified material delivery route system.

Published in: Business, Technology

Supermarket delivery system

  1. 1. SUPERMARKET DELIVERY SYSTEM By: Matt Wrye Beyond Lean Product min Work Area Product in IPK Product min Work Area P01 P01 P01 P02 P02 P02 P03 P04 P04 P02 P02 P01 2 of 3 XE-90 P02 1 of 3 XE-90 & INSIGHT P03 P03 1 of 1 Coil P04 1 of 2 Coil
  2. 2. What is… <ul><li>A supermarket? </li></ul><ul><ul><li>Centralized storage location of components </li></ul></ul><ul><li>A kanban card? </li></ul><ul><ul><li>Visual card that indicates when to order and when to manufacture a component </li></ul></ul><ul><li>A component delivery route? </li></ul><ul><ul><li>Specified delivery route and timing to deliver components to a work area and pick up kanban cards for next delivery time </li></ul></ul>
  3. 3. Why Use A Supermarket Delivery System? <ul><li>Reduce shortages at the production lines </li></ul><ul><li>Reduce storage of components at the production lines </li></ul><ul><li>Reduce inventory of components in the facility </li></ul><ul><li>Steady delivery of components to the assembly lines </li></ul><ul><li>Flexibility to deliver correct components even if the schedule changes </li></ul><ul><li>Improve overall facility 5S Score </li></ul>
  4. 4. Specifics for this system design: <ul><li>Components are manufactured in the assembly facility </li></ul><ul><li>Component supermarket is adjacent to the component manufacturing area </li></ul><ul><li>Component supermarket feeds multiple assembly lines </li></ul><ul><li>Component supermarket is not located near the assembly lines </li></ul><ul><li>Inventory at the assembly lines is not to exceed 4 hours worth of material </li></ul>
  5. 5. Tub of material stored at the line ready to be used. Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  6. 6. Tub with line dedicated Kanban card moves to assembly to be used Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  7. 7. When the tub is empty the line material handler takes the Kanban card from the “Kanban Empty” bin in the operator station to the scanner station, scans the card and places it in “Kanban Ordered” bin The empty tub is returned to component manufacturer Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  8. 8. When the Kanban card is scanned a signal is sent to the Supermarket ordering another tub of parts Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  9. 9. When the trigger level is reached in the Supermarket a job is kicked off electronically in component manufacturer Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  10. 10. When the component manufacturer finishes a job a white Kanban Ticket is added to the tub and the tub is moved to the Supermarket to be stored Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  11. 11. Supermarket attendant pulls orders from the shelves and puts the tub on the pallet for the line that ordered it Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  12. 12. Every 2 hours a material handler delivers the pallet from the Supermarket to the line Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  13. 13. Line material handler matches P/N on white Kanban card with P/N on green Kanban card . If they match the white Kanban card is thrown away and the green Kanban card is placed on the tub Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  14. 14. The line material handler then moves the tub with the green Kanban card to the line storage shelves Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  15. 15. Tub of material stored at the line ready to be used. Assembly Line Storage Supermarket Component Mfg Scanner Station Line Incoming Line Pallet
  16. 16. Supermarket Container Ticket Information: <ul><li>Part Number </li></ul><ul><li>Description </li></ul><ul><li>Quantity </li></ul><ul><li>Ticket Serial Number </li></ul><ul><li>Barcode </li></ul><ul><li>Bay Location in Supermarket </li></ul>
  17. 17. Kanban Card Design: <ul><li>Part number </li></ul><ul><li>Card sequence number (1 of …) </li></ul><ul><li>Assembly Line Number </li></ul><ul><li>Assembly Line specific color (Ex: Line 1 = Blue) </li></ul><ul><li>Container type </li></ul><ul><li>Quantity </li></ul><ul><li>Barcode </li></ul>
  18. 18. Next Steps: <ul><li>Calculate four hour target inventory </li></ul><ul><ul><li>At each line </li></ul></ul><ul><ul><li>By part number </li></ul></ul><ul><li>Determine flow of containers </li></ul><ul><ul><li>Into supermarket from Tube Fab </li></ul></ul><ul><ul><li>From supermarket to lines </li></ul></ul><ul><li>Fork truck delivery rates to each line </li></ul><ul><li>Supermarket staffing requirement </li></ul><ul><li>Finalize supermarket container storage requirement </li></ul><ul><li>Material handling within supermarket </li></ul>

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