Overview

This 2 day workshop will teach you how to move and handle purchased parts from the receiving door to the shipping door. The focus is on designing and implementing a system that reliably supplies purchased parts to continuous-flow cells, small-batch processing, and traditional assembly lines. The design and management of all aspects of a comprehensive Lean material handling system are covered, including routing, kanban systems and parts markets, as well as sustaining and continuously improving the system.

Those who would benefit from attending this workshop include:

• Material handling and production control personnel, managers, supervisors, operations and support personnel, and change agents.
• Organizations that require purchased parts for production.
• Organizations that have had some experience implementing lean elsewhere in the organization.

Approach

Through instruction, discussion, case studies and hands-on workshop exercises, this workshop uses realistic factory examples to provide the concepts and the practical know-how you need to plan and implement the transition to a Lean system. The use of formulas, forms, rules and checklists are reviewed in detail, as are the detailed steps for the design and implementation of a parts database, parts markets, pull systems and optimized routes.

What You Will Learn

Workshop content includes:

• Developing and using a parts management database to drive and control inventory reduction and continuous system improvement.
• Designing and building a purchased-parts market and managing inventory levels.
• Parts movement and conveyance options from parts markets to manufacturing.
• Designing optimal delivery routes.
• Calculating material delivery times.
• The types and uses of pull signals.
• Creating and operating pull systems
• Design for sustainability and continuous improvement:
• Standard work for the materials department
• System metrics and objectives
• Closed loop management controls
• Layered auditing
• Continuous system improvement

Training Outcomes

This workshop provides the knowledge and tools needed to systematically develop, operate and continuously improve a facility-wide lean material delivery system for purchased parts. System benefits include:

• Reduced costs:
  • Reduced material handling costs.
  • Less time and hassle retrieving parts.
  • Higher plant inventory turns.
  • Less inventory.
  • Fewer forklifts.
  • Less overtime.
  • Less expedited delivery costs
• Higher production output:
  • Increased reliability: the right part, delivered on time and in the right quantity to the operator
• Improved safety:
  • Fewer forklift recordable incidents.

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