The document discusses pull systems and pull signals. It defines pull systems as methods for controlling resource flow by replacing only what has been consumed. It describes different types of pull signals like cards, container exchanges, and light boards that are used to signal the need to replenish consumed materials. It also addresses factors involved in implementing pull systems like processes, economics, logistics, and space considerations.
The document discusses pull systems and how they work. It defines pull systems as methods for controlling the flow of resources by replacing only what has been consumed. It contrasts this with push systems, which provide resources based on forecasts. It provides examples of how pull signals like cards or containers can be used to trigger the replenishment of consumed materials.
This document discusses concepts of lean production and just-in-time (JIT) systems. It outlines that JIT began in Japan in the 1970s in response to an oil crisis, with a focus on reducing waste. Key aspects of lean/JIT discussed include the Kanban system using cards to trigger production, reducing inventory and uncertainties. The document provides an example calculating the size and number of Kanban containers needed based on production data. It concludes that while Kanban uses a pull system, master scheduling still plays a role to effectively plan at the front end.
The document discusses a spike in demand for Schneider Electrical's new STAR UPS model that will require increasing production capacity by 700% within one month. The current plant produces 15,000 units per month across two shifts but will need to produce 37,000 units, primarily of the STAR model, to meet demand. This presents challenges in increasing production capacity given budget constraints. Recommendations include adding a third production shift, procuring additional testing machines to remove bottlenecks, optimizing processes, managing suppliers and vendors to ensure material flow, and implementing structural changes like changing to a cellular layout.
The document discusses various aspects of manufacturing plant design including plant layouts, scheduling, and inventory management. It provides details on different types of plant layouts such as functional, product, and cellular layouts. It also covers topics like single machine scheduling, parallel machine scheduling, critical path analysis, economic order quantity, and master production scheduling. Plant location selection and material requirement planning are analyzed through examples and formulas. The document is an in-depth reference on manufacturing design and production planning concepts.
The document discusses various aspects of manufacturing plant design including plant layouts, production scheduling, and inventory management. It provides details on different types of plant layouts such as functional, product, and cellular layouts. It also covers topics like single machine scheduling, parallel machine scheduling, critical path analysis, economic order quantity, and master production scheduling. Plant location selection and designing a cellular layout with machine allocation are demonstrated through examples. The key aspects covered are plant layout design, scheduling operations, materials requirement planning, and inventory management techniques.
1. The document summarizes productivity improvement efforts for a production line at WABCO. A team analyzed data on cycle times, outputs, WIP levels, and identified causes for low productivity such as imbalanced cycle times and unnecessary movements.
2. The team conducted experiments to optimize cycle times on critical machines like CNC machines through Design of Experiments. They also combined operations, improved fixtures, implemented a cell layout, and modified material handling.
3. These countermeasures helped reduce cycle times and WIP, increase output to meet rising demand, and boost productivity and efficiency on the production line.
The document discusses inventory management. It describes the objectives of inventory management as understanding inventory functions and concerns, management techniques, and determining optimal order quantities. The key inventory costs discussed are holding, ordering, and setup costs. Different inventory models are introduced, including economic order quantity, production order quantity, and quantity discount models. Formulas are provided to calculate optimal order quantities that minimize total costs based on the different models.
This document discusses operations management concepts related to process analysis. It introduces the three key metrics for analyzing any process: flow rate, flow time, and inventory. These are explained using examples like a sandwich shop and hospital department. The document also covers identifying and analyzing bottlenecks, calculating capacity, understanding variability and its impacts, different types of inventory, and dealing with multiple flow unit types in a process. The overall goal is to provide tools and methods for evaluating processes and identifying areas for improvement.
The document discusses pull systems and how they work. It defines pull systems as methods for controlling the flow of resources by replacing only what has been consumed. It contrasts this with push systems, which provide resources based on forecasts. It provides examples of how pull signals like cards or containers can be used to trigger the replenishment of consumed materials.
This document discusses concepts of lean production and just-in-time (JIT) systems. It outlines that JIT began in Japan in the 1970s in response to an oil crisis, with a focus on reducing waste. Key aspects of lean/JIT discussed include the Kanban system using cards to trigger production, reducing inventory and uncertainties. The document provides an example calculating the size and number of Kanban containers needed based on production data. It concludes that while Kanban uses a pull system, master scheduling still plays a role to effectively plan at the front end.
The document discusses a spike in demand for Schneider Electrical's new STAR UPS model that will require increasing production capacity by 700% within one month. The current plant produces 15,000 units per month across two shifts but will need to produce 37,000 units, primarily of the STAR model, to meet demand. This presents challenges in increasing production capacity given budget constraints. Recommendations include adding a third production shift, procuring additional testing machines to remove bottlenecks, optimizing processes, managing suppliers and vendors to ensure material flow, and implementing structural changes like changing to a cellular layout.
The document discusses various aspects of manufacturing plant design including plant layouts, scheduling, and inventory management. It provides details on different types of plant layouts such as functional, product, and cellular layouts. It also covers topics like single machine scheduling, parallel machine scheduling, critical path analysis, economic order quantity, and master production scheduling. Plant location selection and material requirement planning are analyzed through examples and formulas. The document is an in-depth reference on manufacturing design and production planning concepts.
The document discusses various aspects of manufacturing plant design including plant layouts, production scheduling, and inventory management. It provides details on different types of plant layouts such as functional, product, and cellular layouts. It also covers topics like single machine scheduling, parallel machine scheduling, critical path analysis, economic order quantity, and master production scheduling. Plant location selection and designing a cellular layout with machine allocation are demonstrated through examples. The key aspects covered are plant layout design, scheduling operations, materials requirement planning, and inventory management techniques.
1. The document summarizes productivity improvement efforts for a production line at WABCO. A team analyzed data on cycle times, outputs, WIP levels, and identified causes for low productivity such as imbalanced cycle times and unnecessary movements.
2. The team conducted experiments to optimize cycle times on critical machines like CNC machines through Design of Experiments. They also combined operations, improved fixtures, implemented a cell layout, and modified material handling.
3. These countermeasures helped reduce cycle times and WIP, increase output to meet rising demand, and boost productivity and efficiency on the production line.
The document discusses inventory management. It describes the objectives of inventory management as understanding inventory functions and concerns, management techniques, and determining optimal order quantities. The key inventory costs discussed are holding, ordering, and setup costs. Different inventory models are introduced, including economic order quantity, production order quantity, and quantity discount models. Formulas are provided to calculate optimal order quantities that minimize total costs based on the different models.
This document discusses operations management concepts related to process analysis. It introduces the three key metrics for analyzing any process: flow rate, flow time, and inventory. These are explained using examples like a sandwich shop and hospital department. The document also covers identifying and analyzing bottlenecks, calculating capacity, understanding variability and its impacts, different types of inventory, and dealing with multiple flow unit types in a process. The overall goal is to provide tools and methods for evaluating processes and identifying areas for improvement.
This document discusses various inventory management techniques. It begins by defining inventory and the objective of inventory management. It then describes the different types of inventory including raw materials, work-in-process, maintenance/repair/operating supplies, and finished goods. Several inventory management techniques are covered, including ABC analysis for prioritizing inventory items, cycle counting to maintain accurate records, and controlling service inventories. Inventory models like economic order quantity, production order quantity, quantity discounts, and probabilistic models are also summarized.
The document provides an overview of the operations at Anoplate, a metal finishing company. It describes the key processes from receiving customer orders through planning, scheduling, racking, and plating. Issues identified include long wait times between receiving and racking, missed on-time delivery commitments, inaccurate projected start dates, and preferential treatment of premium customers. Recommendations are made to streamline processes, improve planning and scheduling software, track rack locations, and set more accurate projected dates.
This document discusses strategies for reducing lead times in supply chains. It defines lead time as the time it takes to complete an operation or process. Long lead times are caused by factors like setup times, wait times, and decision-making delays. The key is to map the current supply chain process and identify non-value-added activities. Reducing lead times can increase capacity and sales by cutting bottlenecks. Strategies include line balancing to even out workloads, reducing complexity, and integrating processes through automation. Measuring and comparing production and customer demand times helps determine where to focus optimization efforts.
This document discusses a proposed project to improve electrical power efficiency at a manufacturing plant. It includes:
1) An analysis of the current issues with high electricity consumption and production losses due to outdated machinery and lack of motor controls. Electricity usage is 24% of total power and production losses are 30 hours per month.
2) The project aims to replace wiring, equipment, and install a PLC and VFDs to reduce power consumption by 25% and save costs. This will allow investing savings into new projects.
3) A feasibility study evaluates the technical, economic, legal and organizational aspects of the project. It provides cost estimates and a scheduled timeline of 4 weeks to complete the work.
Overall Project Review - Paper Furnish Optimization3Paul Bullock
This document outlines a Lean Six Sigma project to optimize the paper furnish handling and processing at a gypsum wallboard manufacturing plant in order to reduce paper costs, including defining key terms, mapping the current process, collecting baseline data on furnish attributes and paper quality, and analyzing current performance to identify potential root causes of variability. The project follows the DMAIC methodology and utilizes various Lean and Six Sigma tools to guide the improvement process.
Andre Gibson from Key Engineering discusses how to improve productivity through process optimisation. This presentation was initially discussed at the TPM2015 conference.
LINE CALL REDUCTION USING PROCESS IMPROVEMENT IN AN AUTOMOBILE COMPANY: A SIM...Michael George
The aim of this paper is to decrease the chances of inventory going below the set minimum by eliminating the factors causing shortages and delays. When inventory goes below set minimum it is then called as line call, where the customer (Set Part Supply Department) demands immediate supply of those product undergoing shortage. The aim is to reduce the number of line calls by eliminating root causes for line calls. The reasons for line calls will be identified using root cause analysis and after studying the causes, counter measures for each cause will be identified and implemented. Some of these measures involve in changing processes and adding new equipment to reduce overall work and some involve statistically finding the problem areas in the data set. After all the two counter measures were implemented, we were able to reduce 85% of overall line calls leading to a large saving to the plant in terms of equipment area and man power. Also with the implementation of this concept, work burden to employees is reduced, thus creating an enjoyable work place.
Kanban is a scheduling system that uses visual signals, often cards or bins, to trigger production and replenishment. There are several types of kanban systems including basic, pull-style, and supermarket-style. Kanban signals can be physical cards or electronic signals. The kanban rule dictates that no items are produced without a kanban signal. Kanban size is calculated based on factors like takt time, average demand, lead time, and container size. Kanban circulation involves transportation and wait times at each production step.
This document describes Delta Air Lines' expendable parts inventory management system. It discusses key considerations like when to order parts and how much to order. It also outlines the various costs involved like ordering costs, carrying costs, and stockout costs. The goal is to minimize total quantifiable costs while meeting a target customer service level. The system uses a reorder point-reorder quantity model and safety stocks to prevent stockouts. It provides an example of how the economic order quantity is calculated and how safety stocks are determined. The system was implemented in 1996 and provided tangible cost savings and intangible benefits in optimizing inventory levels.
The document describes the automation of labour reporting at a depot through a Kaizen process.
The initial labour reporting process was paper-based, time-consuming, and prone to errors. Team Leaders would manually record hours on paper sheets that were then transferred to electronic sheets by administrators. This created inefficiencies.
Through Kaizen proposals, an electronic database was created to automate the reporting. Data from individual workstations was automatically compiled into daily reports with minimal effort. This saved over 18 manhours per day and €54,500 annually while improving accuracy and providing standardized daily feedback. Employees and managers recognized benefits including improved productivity tracking and root cause analysis capabilities.
The document discusses key concepts in Material Requirements Planning (MRP), including:
1) MRP addresses the simultaneous probability problem by accounting for the likelihood that all components of an end item will be available at the same time for production.
2) Product structures, recurring requirements, multilevel items, and rescheduling open orders are challenges in computing accurate requirements in MRP.
3) Lot sizing techniques like lot-for-lot, economic order quantity, and period order quantity impact load levels at work centers.
4) Safety stocks are needed in MRP to address demand and supply variations; options include fixed quantity buffers, increasing safety lead times, or inflating gross requirements.
The document discusses key concepts in Material Requirements Planning (MRP), including:
1) MRP addresses the simultaneous probability problem by accounting for the likelihood that all component items will be available at the same time to produce the end item.
2) MRP computations are impacted by the product structure, recurring requirements within the planning horizon, multilevel items, and rescheduling open orders.
3) MRP involves decisions around regeneration vs. net change updates, lot sizing techniques, and establishing appropriate safety stocks.
1. The document provides details on 10 projects aimed at tactical supply chain improvements, including revising MRP parameters to reduce inventory levels, implementing kanban systems for small parts, and analyzing obsolete materials.
2. Methodologies used include analyzing manufacturing and ordering times in SAP, creating kits to optimize material supply, and monitoring small parts racks. Improvements include reduced inventory levels, improved information flow, and increased warehouse efficiency.
3. The status of each project is indicated as finished, in progress, or finalized, with further work noted for some projects to expand scope or automate processes.
Daniel Cahalarn implemented a completions driven approach on the Hebron oil field project in Korea that resulted in significant benefits. By utilizing progressive inspections with a mobile 3D model, they were able to validate cable tray installation 25% faster. This improved schedule certainty and identified opportunities to pull more cable per week. Visualizing the status in 3D also found early loop testing opportunities. Overall, the approach improved safety, quality, and construction performance through focused planning, inspections, and influencing contractor behavior with accurate information.
The document defines key terms related to process analysis such as process, cycle time, and utilization. It describes how process flowcharting can be used to diagram major process elements like tasks, decisions, and flows. Common flowchart symbols are defined. The document also discusses different types of processes like single-stage, multi-stage, make-to-order, and make-to-stock. Various process performance metrics are introduced like throughput time, velocity, cycle time, and utilization. Finally, the document covers different process types like continuous, batch, repetitive/assembly line, and job shop.
Garuda Robotics x DataScience SG Meetup (Sep 2015)Eugene Yan Ziyou
What exactly goes on in the commercial drone/UAV industry in Singapore and globally? Behind the hype of consumer “selfie” drones lies a vast number of interesting commercial applications, where drones become an enabler for enterprises to gain new aerial perspectives of their facilities and estates, to make intelligent decisions incorporating this additional dimension of data.
In this presentation, we will look at one such drones-at-work application to reveal some of the behind-the-scene processes and technologies employed. Specifically, we will dive into the precision agriculture domain and share some of the computer vision problems we face, and take a look at various potential solutions to these challenges.
KEY TO PROFITABILITY: SPARE PART MANAGEMENTDr. V.N. Tikku
Many companies fail not because of more consumption but due to maintenance of huge spare inventory which remains underutilized ! The presentation looks in to reasons as well as remedial actions...
This document provides an overview and introduction to demand flow technology (DFT) principles and techniques for lean manufacturing. It discusses key DFT concepts like total product cycle time, takt time, line balancing, kanban systems, mixed model production, and measuring production linearity. The objectives are to develop knowledge of DFT philosophies and techniques, understand the total business strategy, and learn how to establish and perform the skills like setting operational standards and synchronizing production processes.
The document provides information about value stream mapping (VSM). It begins with an introduction to VSM, explaining that a value stream map shows all elements from raw materials to delivery for a given product. It then provides details on the current state mapping process, including forming a cross-functional team, understanding customer demand, mapping the process, material and information flows, calculating total cycle time, and detailing off-line activities. Examples of current state maps are also included to demonstrate how the process is mapped.
The document discusses operations management concepts related to just-in-time (JIT), lean operations, and the Toyota Production System (TPS). It defines key terms like JIT, TPS, the seven wastes, and the 5Ss. It explains that JIT aims to eliminate waste and reduce variability through techniques like kanban signaling, small lot sizes, setup time reduction, and level scheduling. TPS emphasizes continuous improvement, respect for people, and standard work practices to optimize production. Lean operations focus on understanding customer wants and needs to optimize the entire production process.
Adani Group's Active Interest In Increasing Its Presence in the Cement Manufa...Adani case
Time and again, the business group has taken up new business ventures, each of which has allowed it to expand its horizons further and reach new heights. Even amidst the Adani CBI Investigation, the firm has always focused on improving its cement business.
This document discusses various inventory management techniques. It begins by defining inventory and the objective of inventory management. It then describes the different types of inventory including raw materials, work-in-process, maintenance/repair/operating supplies, and finished goods. Several inventory management techniques are covered, including ABC analysis for prioritizing inventory items, cycle counting to maintain accurate records, and controlling service inventories. Inventory models like economic order quantity, production order quantity, quantity discounts, and probabilistic models are also summarized.
The document provides an overview of the operations at Anoplate, a metal finishing company. It describes the key processes from receiving customer orders through planning, scheduling, racking, and plating. Issues identified include long wait times between receiving and racking, missed on-time delivery commitments, inaccurate projected start dates, and preferential treatment of premium customers. Recommendations are made to streamline processes, improve planning and scheduling software, track rack locations, and set more accurate projected dates.
This document discusses strategies for reducing lead times in supply chains. It defines lead time as the time it takes to complete an operation or process. Long lead times are caused by factors like setup times, wait times, and decision-making delays. The key is to map the current supply chain process and identify non-value-added activities. Reducing lead times can increase capacity and sales by cutting bottlenecks. Strategies include line balancing to even out workloads, reducing complexity, and integrating processes through automation. Measuring and comparing production and customer demand times helps determine where to focus optimization efforts.
This document discusses a proposed project to improve electrical power efficiency at a manufacturing plant. It includes:
1) An analysis of the current issues with high electricity consumption and production losses due to outdated machinery and lack of motor controls. Electricity usage is 24% of total power and production losses are 30 hours per month.
2) The project aims to replace wiring, equipment, and install a PLC and VFDs to reduce power consumption by 25% and save costs. This will allow investing savings into new projects.
3) A feasibility study evaluates the technical, economic, legal and organizational aspects of the project. It provides cost estimates and a scheduled timeline of 4 weeks to complete the work.
Overall Project Review - Paper Furnish Optimization3Paul Bullock
This document outlines a Lean Six Sigma project to optimize the paper furnish handling and processing at a gypsum wallboard manufacturing plant in order to reduce paper costs, including defining key terms, mapping the current process, collecting baseline data on furnish attributes and paper quality, and analyzing current performance to identify potential root causes of variability. The project follows the DMAIC methodology and utilizes various Lean and Six Sigma tools to guide the improvement process.
Andre Gibson from Key Engineering discusses how to improve productivity through process optimisation. This presentation was initially discussed at the TPM2015 conference.
LINE CALL REDUCTION USING PROCESS IMPROVEMENT IN AN AUTOMOBILE COMPANY: A SIM...Michael George
The aim of this paper is to decrease the chances of inventory going below the set minimum by eliminating the factors causing shortages and delays. When inventory goes below set minimum it is then called as line call, where the customer (Set Part Supply Department) demands immediate supply of those product undergoing shortage. The aim is to reduce the number of line calls by eliminating root causes for line calls. The reasons for line calls will be identified using root cause analysis and after studying the causes, counter measures for each cause will be identified and implemented. Some of these measures involve in changing processes and adding new equipment to reduce overall work and some involve statistically finding the problem areas in the data set. After all the two counter measures were implemented, we were able to reduce 85% of overall line calls leading to a large saving to the plant in terms of equipment area and man power. Also with the implementation of this concept, work burden to employees is reduced, thus creating an enjoyable work place.
Kanban is a scheduling system that uses visual signals, often cards or bins, to trigger production and replenishment. There are several types of kanban systems including basic, pull-style, and supermarket-style. Kanban signals can be physical cards or electronic signals. The kanban rule dictates that no items are produced without a kanban signal. Kanban size is calculated based on factors like takt time, average demand, lead time, and container size. Kanban circulation involves transportation and wait times at each production step.
This document describes Delta Air Lines' expendable parts inventory management system. It discusses key considerations like when to order parts and how much to order. It also outlines the various costs involved like ordering costs, carrying costs, and stockout costs. The goal is to minimize total quantifiable costs while meeting a target customer service level. The system uses a reorder point-reorder quantity model and safety stocks to prevent stockouts. It provides an example of how the economic order quantity is calculated and how safety stocks are determined. The system was implemented in 1996 and provided tangible cost savings and intangible benefits in optimizing inventory levels.
The document describes the automation of labour reporting at a depot through a Kaizen process.
The initial labour reporting process was paper-based, time-consuming, and prone to errors. Team Leaders would manually record hours on paper sheets that were then transferred to electronic sheets by administrators. This created inefficiencies.
Through Kaizen proposals, an electronic database was created to automate the reporting. Data from individual workstations was automatically compiled into daily reports with minimal effort. This saved over 18 manhours per day and €54,500 annually while improving accuracy and providing standardized daily feedback. Employees and managers recognized benefits including improved productivity tracking and root cause analysis capabilities.
The document discusses key concepts in Material Requirements Planning (MRP), including:
1) MRP addresses the simultaneous probability problem by accounting for the likelihood that all components of an end item will be available at the same time for production.
2) Product structures, recurring requirements, multilevel items, and rescheduling open orders are challenges in computing accurate requirements in MRP.
3) Lot sizing techniques like lot-for-lot, economic order quantity, and period order quantity impact load levels at work centers.
4) Safety stocks are needed in MRP to address demand and supply variations; options include fixed quantity buffers, increasing safety lead times, or inflating gross requirements.
The document discusses key concepts in Material Requirements Planning (MRP), including:
1) MRP addresses the simultaneous probability problem by accounting for the likelihood that all component items will be available at the same time to produce the end item.
2) MRP computations are impacted by the product structure, recurring requirements within the planning horizon, multilevel items, and rescheduling open orders.
3) MRP involves decisions around regeneration vs. net change updates, lot sizing techniques, and establishing appropriate safety stocks.
1. The document provides details on 10 projects aimed at tactical supply chain improvements, including revising MRP parameters to reduce inventory levels, implementing kanban systems for small parts, and analyzing obsolete materials.
2. Methodologies used include analyzing manufacturing and ordering times in SAP, creating kits to optimize material supply, and monitoring small parts racks. Improvements include reduced inventory levels, improved information flow, and increased warehouse efficiency.
3. The status of each project is indicated as finished, in progress, or finalized, with further work noted for some projects to expand scope or automate processes.
Daniel Cahalarn implemented a completions driven approach on the Hebron oil field project in Korea that resulted in significant benefits. By utilizing progressive inspections with a mobile 3D model, they were able to validate cable tray installation 25% faster. This improved schedule certainty and identified opportunities to pull more cable per week. Visualizing the status in 3D also found early loop testing opportunities. Overall, the approach improved safety, quality, and construction performance through focused planning, inspections, and influencing contractor behavior with accurate information.
The document defines key terms related to process analysis such as process, cycle time, and utilization. It describes how process flowcharting can be used to diagram major process elements like tasks, decisions, and flows. Common flowchart symbols are defined. The document also discusses different types of processes like single-stage, multi-stage, make-to-order, and make-to-stock. Various process performance metrics are introduced like throughput time, velocity, cycle time, and utilization. Finally, the document covers different process types like continuous, batch, repetitive/assembly line, and job shop.
Garuda Robotics x DataScience SG Meetup (Sep 2015)Eugene Yan Ziyou
What exactly goes on in the commercial drone/UAV industry in Singapore and globally? Behind the hype of consumer “selfie” drones lies a vast number of interesting commercial applications, where drones become an enabler for enterprises to gain new aerial perspectives of their facilities and estates, to make intelligent decisions incorporating this additional dimension of data.
In this presentation, we will look at one such drones-at-work application to reveal some of the behind-the-scene processes and technologies employed. Specifically, we will dive into the precision agriculture domain and share some of the computer vision problems we face, and take a look at various potential solutions to these challenges.
KEY TO PROFITABILITY: SPARE PART MANAGEMENTDr. V.N. Tikku
Many companies fail not because of more consumption but due to maintenance of huge spare inventory which remains underutilized ! The presentation looks in to reasons as well as remedial actions...
This document provides an overview and introduction to demand flow technology (DFT) principles and techniques for lean manufacturing. It discusses key DFT concepts like total product cycle time, takt time, line balancing, kanban systems, mixed model production, and measuring production linearity. The objectives are to develop knowledge of DFT philosophies and techniques, understand the total business strategy, and learn how to establish and perform the skills like setting operational standards and synchronizing production processes.
The document provides information about value stream mapping (VSM). It begins with an introduction to VSM, explaining that a value stream map shows all elements from raw materials to delivery for a given product. It then provides details on the current state mapping process, including forming a cross-functional team, understanding customer demand, mapping the process, material and information flows, calculating total cycle time, and detailing off-line activities. Examples of current state maps are also included to demonstrate how the process is mapped.
The document discusses operations management concepts related to just-in-time (JIT), lean operations, and the Toyota Production System (TPS). It defines key terms like JIT, TPS, the seven wastes, and the 5Ss. It explains that JIT aims to eliminate waste and reduce variability through techniques like kanban signaling, small lot sizes, setup time reduction, and level scheduling. TPS emphasizes continuous improvement, respect for people, and standard work practices to optimize production. Lean operations focus on understanding customer wants and needs to optimize the entire production process.
Adani Group's Active Interest In Increasing Its Presence in the Cement Manufa...Adani case
Time and again, the business group has taken up new business ventures, each of which has allowed it to expand its horizons further and reach new heights. Even amidst the Adani CBI Investigation, the firm has always focused on improving its cement business.
Revolutionizing Surface Protection Xlcoatings Nano Based SolutionsExcel coatings
Excelcoating Transforming surface protection with their cutting-edge, eco-friendly nano-based coatings. This presentation delves into their innovative product lineup, including Excel CoolCoat for roof cooling, Excel NanoSeal for cement surfaces, Excel StayCool for UV-filtering glass, Excel StayClean for solar panels, Excel CoolTile for heat-reflective tiles, and Excel InsulX for film insulation.
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L'indice de performance des ports à conteneurs de l'année 2023SPATPortToamasina
Une évaluation comparable de la performance basée sur le temps d'escale des navires
L'objectif de l'ICPP est d'identifier les domaines d'amélioration qui peuvent en fin de compte bénéficier à toutes les parties concernées, des compagnies maritimes aux gouvernements nationaux en passant par les consommateurs. Il est conçu pour servir de point de référence aux principaux acteurs de l'économie mondiale, notamment les autorités et les opérateurs portuaires, les gouvernements nationaux, les organisations supranationales, les agences de développement, les divers intérêts maritimes et d'autres acteurs publics et privés du commerce, de la logistique et des services de la chaîne d'approvisionnement.
Le développement de l'ICPP repose sur le temps total passé par les porte-conteneurs dans les ports, de la manière expliquée dans les sections suivantes du rapport, et comme dans les itérations précédentes de l'ICPP. Cette quatrième itération utilise des données pour l'année civile complète 2023. Elle poursuit le changement introduit l'année dernière en n'incluant que les ports qui ont eu un minimum de 24 escales valides au cours de la période de 12 mois de l'étude. Le nombre de ports inclus dans l'ICPP 2023 est de 405.
Comme dans les éditions précédentes de l'ICPP, la production du classement fait appel à deux approches méthodologiques différentes : une approche administrative, ou technique, une méthodologie pragmatique reflétant les connaissances et le jugement des experts ; et une approche statistique, utilisant l'analyse factorielle (AF), ou plus précisément la factorisation matricielle. L'utilisation de ces deux approches vise à garantir que le classement des performances des ports à conteneurs reflète le plus fidèlement possible les performances réelles des ports, tout en étant statistiquement robuste.
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Adani Group Requests For Additional Land For Its Dharavi Redevelopment Projec...Adani case
It will bring about growth and development not only in Maharashtra but also in our country as a whole, which will experience prosperity. The project will also give the Adani Group an opportunity to rise above the controversies that have been ongoing since the Adani CBI Investigation.
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2. Pull System
Definition:
A method of controlling the
flow of resources by
replacing only what has
been consumed.
Pull Signals Pull Process
Material At
Operator
Manpower
WASTE
6. •
Requirement
s
- Fresh
- Available
- Brand
- Price
- Size
Capacit
y
Deman
d
On Time
Delivery
FIFO
Rotate Stock
Quality
Cost
Supply
• Requirements
-
Communications
- Specifications
- Expectations
- Timing
GROCERIES
J.I.T
Customer Pull
7. Synchronous / Lean Manufacturing
Pull System
75
¢
m
m
m
m
m
m&
m
m&
m
m&
m
m&
m
m&
m
m&
m
m&
m
m
E
M
P
T
Y
mmm
n
mmm
n
mmm
n
mmm
n
mmm
n
mmm
n
mmm
n
mmm
n
Provider Consumer
Replaces
Used
Products
Uses
Products
m&
m
9. Push vs. Pull
Make all we can
just in case.
Make what’s needed
when we need it
• Production Approximation
• Anticipated Usage's
• Large Lots
• High Inventories
• Waste
• Management by Firefighting
• Poor Communication
• Production Precision
• Actual Consumption
• Small Lots
• Low Inventories
• Waste Reduction
• Management by Sight
• Better Communication
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
PART
S
10. A Pull System Is Flexible and
Simple
Objectives:
• Methods of controlling and balancing the flow
Of resources.
• Eliminating waste of handling, storage, expediting,
Obsolescence, repair, rework, facilities, equipment,
Excess inventory (work-in-process & finished).
• Manufacture and ship only what has been
Consumed.
• Provides visual control of all resources.
11. Pull Signals
NUMBER QUANTITY
WIDGET
ADDRESS
1 2 3
4 5 6
7 8 9
Electroni
c
Signals
Instruction Sent From the Consumer to
the Provider to Replace Resources
that have been Used
Compute
r
Signals
Card
s
EMPTY
Containe
r
Exchang
e
12. Example of an “Internal” Pull Signal
Visual Control Board
Informatio
n
13. Pull Signal - Card
Point of
Manufacturin
g
Point
of
Use
Standar
d
Pack
Containe
r
Standar
d
Pack
Quantit
y
Descriptio
n
Part
Number
Designat
ed
Storage
Area
STORE
MN
10/12/98
14. Reverse side of Pull Signal Card
If found,
return to
MA, or ship.
area
Thank You
10/12/98
15. Pull - Loop Flow Diagram
Pull Signal
Material with Pull
Signal
Visual
Control
Board
Weld
Test
Assembl
y
Pipe
Sho
p
4 3
1
2,5
6
10/12/98
16. De-Coupled Pull Process
8:00 Card / delivery person walks by, picking
up cards while delivering material
8:05 Operator puts out card “A”
9:00 Card delivery person walks by, gets
Card “A”
10:00 Card “A” material is filled by supermarket
Person
11:00 Card “A” material is delivered to the
Operator
Need Minimum 3 Hours of Material
At the Operator
10/12/98
19. Pull Signals
CONTAINER OR DOLLY EXCHANGE
Uses the empty container as a physical signal that authorizes
The replenishment of the consumed material.
• Requires space for two containers
• Operator must draw from one
container
At a time
• Bulky material
EMPTY
10/12/98
20. Why a Standard Pack?
Specific number of parts = 1 Container of
parts
1 Standard pack = 1 Pull
signal
1 Container of parts = 1 Standard
pack
Supplie
r
Toy
Co..
Part
Numbe
r
Toy
Strut
Custom
er
K2 Dock
Lot
Siz
e
Seq..
No.
=
Pull Signals
CONTAINER OR DOLLY EXCHANGE
10/12/98
22. Pull Signals
MATERIAL LIGHT BOARD
Uses lights to signal the need for bulk material replenishment
At a pre-determined re-order point.
• Operator sensitive
• Re-order point calculation is critical
• Large, non-hand carriable
containers
• Container is fork lift compatible
• Use as last-resort solution
PART #
1234567
PART #
1234567
PART #
1234567
PART #
1234567
PART #
1234567
PART #
1234567
10/12/98
27. Internal Loop Planning
Pull System Coordinator
• Plant/area pull
coordinator
Supplier
• Operator
• Supervisor
• Process
Engineer
Customer
• Operator
• Supervisor
• Material
Handling
10/12/98
28. How Many Pull Signals?
What should be considered in establishing
maximum inventory levels?
• Long changeover times
• Long lead times
• Machine downtime
• Schedule increases / decreases
• Large process or transfer batch
sizes
• Poor quality
• Long cycle times
• Bottleneck operations
10/12/98
29. Pull Signal Monitoring — Case 1
Interpretation:
• Customer requirements are being met.
• Low level of finished goods is maintained.
• Small lot sizes are produced on a regular
basis.
• Ability to changeover is not a problem.
• Opportunity exists to remove signals from
the loop.
Max Signals in
Loop
Red
Zone
Yellow
Zone
Green
Zone
#
Signals
On
Board
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Days
10/12/98
30. Pull Signal Monitoring — Case 2
Interpretation:
• Department runs on the verge of not satisfying customer
requirements.
• Low level of finished goods is maintained.
• Problems may exist that prevent department from getting out of the
danger zone (e.g., quality, downtime, changeovers.)
• By not running into the yellow and green zones, the department is
unable to maintain the desired amount of safety stock.
Max Signals in
Loop
Red
Zone
Yellow
Zone
Green
Zone
#
Signals
On
Board
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Days
10/12/98
31. Pull Signal Monitoring — Case 3
Interpretation:
• Customer requirements are being met.
• High level of finished goods is maintained.
• Department is producing more pull signals than required by
customer.
• Changeovers are not a problem; machinery may be dedicated.
• Too many signals in the loop.
Max Signals in
Loop
Red
Zone
Yellow
Zone
Green
Zone
#
Signals
On
Board
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Days
10/12/98
32. Pull Signal Monitoring — Case 4
Interpretation:
• Large batch sizes are run.
• Changeovers are infrequent.
• Customer may not return pull signals on a frequent basis.
• Process problems may prevent department from running
smoothly.
Max Signals in
Loop
Red
Zone
Yellow
Zone
Green
Zone
#
Signals
On
Board
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Days
10/12/98
33. How Will Pull System Change
Your Job?
• Preventative
maintenance
• Quality improvements
• Team meetings
• Housekeeping
• Training
• Continuous improvement
Pull system provides more time for constructive activities
that will make your job and working conditions better
tomorrow because with pull you run only the parts that
are needed. Shut down time can be spent on:
10/12/98
34. Implementation of a Pull System
Is Affected by Many Factors
• The process itself
• Economics
• Cost and availability of
transportation
• Relationship and logistics of supplier
• Level scheduling
• Containerization
• Supplier, customer, and warehouse
Floor space
These are the reasons why there are only guidelines and not concrete
rules governing the implementation of pull systems. Real data and
common sense must be applied.
10/12/98
35. Benefits of Pull Systems
• Increases employee involvement
• Allows decision-making at appropriate levels
• Allows manufacture of only what is needed by
the customer
• Improves communications of customer needs
through visual controls
• Provides a common system for moving
material
through a plant
10/12/98
36. Benefits of Pull Systems
Continued
• Eliminates scheduling complexities
• Reduces lead time and work in process
inventory
• Highlights quality issues quickly
• Organizes the workplace
• Leads to lower unit cost
• Supports continuous improvements
• Counts inventory by counting number of pull
signals
10/12/98
37. Standard Pack:
1 standard pack = 1 container = 1 pull signal
1 days production = ( )
1 standard pack = 1 days production / 10
( ) = ( ) / 10
Maximum Inventory Level (Max):
Weekly average = 8 weeks inventory / 8
( ) = ( ) / 8
Days of inventory = weekly average / planned daily production
( ) = ( ) / ( )
Safety stock *s.s.) = additional inventory that must be added due
to current non-synchronized operations.
MAX = (days of inventory) X (daily planned production) + (s.s.)
( ) = ( ) X ( ) + ( )
Minimum inventory level (MIN):
(MIN) = batch size = red zone = replenishment
(MIN) = ( )
Number of Pull Signals in a Loop (nps)*:
(nps) = (MAX) / number of pieces in a standard pack
( )* = ( ) / ( )
Number of Pull Signals in a Red Zone (RZ)*:
(RZ) = (MIN) / pieces in a standard pack
( )* = ( ) / ( )
Number of Pull Signals in a Yellow Zone (YZ)*:
(YZ) = (nps) - (RZ) / 2
( )* = (( ) - ( )) / 2
Number of Pull Signals in a Green Zone (GZ)*:
(GZ) = (nps) - (RZ) - (YZ)
( ) = ( ) - ( ) - ( )
Designated Storage (dss):
(dss) = (nps) X (length) X (width) / number of containers high
( ) = ( ) X ( ) X ( ) / ( )
* Round up to the next highest number
/ Means divided by
X Means multiplied by
Pull Signal Calculations
10/12/98
38. Key Point Observations
Pull Systems
(Replenishment based on
consumption)
Pull Signals
(Type used & why)
Inventory Levels
(Stock, WIP, banks)
Stock Dates
(FIFO vs. FISH)
Distance Traveled
(Part, WIP,conveyor lengths)
Small Lot Production
(Minimum material quantity
and flow)
Containerization
(Quality part presented to
operator)
Supplier Involvement
(External of process or
obvious boundary)
Leveling
(Smooth flow vs. too much / little
work, equipment, facilities, people)
Observation Worksheet: Pull System