WHY IT WAS DONE
- To create kits for specific pumps in stores for assembly to pull
- A need to create a pull from assembly
- A need to locate where those kits will be held before and after the pull (both in stores and in assembly)
WHAT WAS DONE
- Training in Takt, Flow and Pull
- Placemats created for specific pump kits – poke yoke
- Named the carts
- Identified and red tagged old inventory
- Created a new cell layout for the cage and staging area to promote flow
- Established a method to refuse incomplete orders
- Purchase orders from our vendors that come early, are just as bad as those that come late.
- Old inventory that is obsolete should be removed
- Setting min/max levels on all stock items in inventory is an easy way to identify if we need more/less.
AND THE RESULTS...
- Identified and red tagged old inventory (top offenders include impellers, casings, rings, cover, motors, etc.)
- Created a method to promote pull from assembly, as well as flow within the stores department.
- Red tagged $$$$ of obsolete inventory
- Mapped the process flow for the carts, and created a new layout for the areas in stores (removing much waste due to transportation).The new cage layout will remove the ‘grocery store-like’ picking of parts
VISUAL CONTROLS AND METRICS
- The new layout of stores will be visual, having a section for power pump parts, horizontal pump parts, vertical pump parts as well as common pump parts
- Placemats will ensure that all parts necessary are on the kit cart, and will draw immediate attention for those parts that are missing.
- New staging area has specific locations for those kits that are complete that can be pulled from assembly.
- Learning from a sensei was a great experience!
- We should have cross-functional teams, as well as have members who know the most about the area
- This will make stores’ and assembly’s life a little more easier to manage
- Making our problems visible is not a negative thing – it’s the only way to highlight problems and come up with ways to fix them.
- I can’t believe we have that much old inventory!