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SYNCHRONIZED MATERIAL FLOW CONCEPT
The implementation of lean manufacturing concepts and specifically the components related to material flow allows manuacturing plants to make enormous improvements . Synchronized Material Flow is a process that produces a continuous flow of material and products, utilizing flexibility and lean manufacturing concepts.
Strengths
· Reduced supply chain (Lead Time)
· Reduced/eliminated work in process (WIP)
· Standardized pull replenishment system
· Reduced risk of “out of stock” incidents
The implementation of pull systems and the synchronization of material flow enables us to produce the right part, in the right quantity at the right time using a leveled schedule and by producing to the customer takt time (demand rate).
The Current State
Manual scheduling done on a regular basis
Manual stock taking done on a regular basis
Abrupt production plan changes
Manual process resulting in lot of errors
No fixed norms for WIP
Non standard packaging
The Future State
System based scheduling
Visual triggers with no manual intervention
WIP levels fixed based on Takt time and throughput time
Standardized packing for similar materials
Pull based production schedules
Improvement Methodology
Card based Kanban systems for In-process assemblies
Visual trigger based systems for Input materials
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