Integrating Kanban with MRP II: Automating a Pull System for Enhanced JIT Inventory Management

by Raymond S. Louis

Overview

Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs.

About the author:

Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of ahandful of candidates selected for a one-year training program conducted by the company‘s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS.

He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales.

Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email: [e-mail]

Product Details

ISBN-13:	9781138471047
Publisher:	Taylor & Francis
Publication date:	11/13/2017
Pages:	248
Product dimensions:	6.00(w) x 9.00(h) x (d)

About the Author

Raymond S. Louis

Table of Contents

Eliminate Replenishment System WasteReplenishment System BasicsAutomated Kanban — The Automated Flow TechnologyKanban Prerequisites — WCM TechniquesImplementing KanbanKanban and MRPII System IntegrationAFT Calculations for Determining Kanban Lot Sizes and Staffing LevelsPerpetuation of the Automated Kanban SystemKey Topics of the Automated Kanban SystemThree examples of AFT Implementation

Editorial Reviews

"Bell Industries, as a supplier, went on the automated kanban system initiated by Raymond Lewis. We found it beneficial from our perspective as it (1) gave us projected visibility to procure our supplies, (2) freed our personnel from manual phone order process, (3) provided consistent releases enhancing our inventory turns, and (4) increased our business levels through the OEM's consolidation of suppliers."

Khamis Refai, General Manager, Bell Industries 04/05/05

"The automated kanban system that Raymond Lewis designed and implemented at Coherent Auburn Group has resulted in significant cost savings."

Robert Gelber, President, Coherent Auburn Group 04/05/05

From the Publisher