MANAGING SYSTEMATIC PRODUCTION UNDESTANDING DRUM – BUFFER - ROPE“Working managers, not managed workers,” is the way of the future
WE TRY TO STUFF A MARSHMELLOW IN A PIGGY BANK EVERY DAY ! DON’T WE?SAY YOUR PAINT BOOTH IS YOUR PIGGY BANK / DRUM DRUM: THE WEAKEST LINK ( PERIOD ) THE SHOP CAN ONLY GET SO MANY LABOR HOURS THROUGH THE PAINT BOOTH IN A DAY OR WEEK. THIS IS CALLED THE DRUM:THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.
• WE THE COMPANY WILL NOW LEARN TOCOORDINATE EVERY THING ELSE AROUND THIS FIXED PLACE.•WE DO SO BY FIXING OUR SYSTEMS “NAIL THEM DOWN” IN ONE PLACE OF MAXIMUM LEVERAGE AT THE CONSTRAINT.
FIXING OUR SYSTEMS “NAIL THEM DOWN”What is gate control?Understanding Replenishment BufferWhat is the drum buffer?Understanding the drumWhat is the shipping gate? How do we Rope / tie it all together DRUM SHIPPING GATE DRUM BUFFER WIP BUFFER
WHAT IS GATE CONTROL ?• Gate control allows Constant Work-In-Process, anddesignates a control strategy that limits the total number oflabor hours allowed into the system at the same time.•The hours are released as they are processed at theconsumption rate of the beat of the drum until they wind upin the last buffer as finished goods. LABOR HRS. ARE RELEASED FROM THE REPLENISHMENT BUFFER GATE DRUM SHIPPING DRUM BUFFER WIP BUFFER
Understanding Replenishment Buffer•Replenishment Buffer management is a control mechanism. The idea behind it can be summarized in the following steps.•Use the Replenishment Buffer to release labor hours as they areprocessed at the consumption rate of the drum.AFTER 1 Disassemble the vehicle , identified parts and labor necessary to repair the vehicle. 2 Verified parts price and availability, Order parts and place vehicle into the staging area. 3 Verified parts by mirror match parts, 4 kit repair for production.
WHAT IS THE DRUM BUFFER ?• ALL OF THE WORK IN PROCESS BETWEEN THE GATE AND THEDRUM CONSTITUTES THE DRUM BUFFER.• ALL OF THEWIP PRIOR TO COMPLETION CONSTITUTES THESHIPPING BUFFER. DRUM BUFFER WIP GATE DRUM SHIPPING
UNDESTANDING DRUM•DRUM: THE WEAKEST LINK IS THE RATE LIMITING STEP.•THE DRUM BEATS OUT THE PRODUCTION RATE FORTHE WHOLE SYSTEM. DRUM GATE DRUM SHIPPING BUFFER WIP BUFFER
WHAT IS THE SHIPPING GATE ?•SHIPPING GATE IS DISCRIBED AS FOLLOWED:• REASSEMBLY OF THE VEHICLE• DETAIL• QUALITY INSPECTION OF FINAL PRODUCT SHIPPING GATE DRUM DRUM BUFFER BUFFER WIP
SYSTEMATIC PRODUCTION VIEW Replenishment buffer GEICO management is key to AIG systemic warehousing and distribution STATE FARMREPLENISHMENT BUFFER DRUM SHIPPING GATE BUFFER DRUM BUFFER WIP
SYSTEMATIC PRODUCTION VIEW GEICO AIG STATE FARM REPAIR WORK COMES IN TO YOUR SHOP WE WILL CALL THIS YOUR PIPE LINE OR FUNNEL
1 Disassemble the vehicle , identified parts and labor necessary to repair the vehicle.2 Verified parts price and availability, Order parts and place vehicle into the staging area REPLENISHMENT BUFFER 3 Verified parts by mirror match parts, 4 kit repair for production.
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 goodsALL OF THE WIP BETWEEN THE GATE AND THE DRUM CONSTITUTES THE DRUM BUFFER.
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 ARELIMITED TO HOW MANY UNITS OR HRS CYCLE THOUGH IT A DAY OR WEEK. THE DRUM BEATS OUT THEMAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.
SHIPPING BUFFERSHIPPING BUFFER IS DISCRIBED AS FOLLOWED: 1 REASAMBLY OF THE VEHICLE 2 DETAIL 3 QUALITY INSPECTION OF FINAL PRODUCT
Thank you for giving me the opportunity to train your company in understandingSystematic production. Now that you understand theprocess 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 FERRESEWV77@HOTMAIL.COM 609 553 4244