Features for a Lean Campaign
Wireless Procurement System – the system processes reorder Kanban Controlled Material with just a scan of the products’ Part Number without paper or the Buyers involvement. The system knows who to procure it from and for what cost. The cost is automatically provided when a Consolidated Vendor Agreement is established, see below.
Plan For Every Part – An effective Lean Campaign incorporates a system that has an PFEP (plan for every part) built in for each part. If it is an internally supplied item, a “make” item, then the BOM associated with that part and Job Order will be supplied to production to replenish that part. If the part is a purchased item, then the external supplier will initiate a replenish order in the predetermined quantity.
Kanban Bins – These bins control dynamic Front Bin and Back Bin quantities. These bins and the inventory status are reportable globally to the organization and provide a visual trigger for product replenishment (see below).
Kanban Signals (Replenishment) – Two types of Kanban initiated replenishment methods are:
1) External to the company – The instant the Kanban reorder signal is identified; its bar code is scanned and an electronic Purchase Order is generated and sent to the vendor via eFAX or Email.
2) Internal to the company – The instant the Kanban reorder signal is identified, a Built-To-Stock Work Order (or Pull Signal) is created which is the fullfiiled in house.
Back Flushing – Inventory is Back Flushed to relive inventory of raw material and add to inventory finished goods or stocked sub assemblies. This maintains perpetual inventory accuracy.
POUI – Incorporating a dynamic Point-Of-Use-Inventory (POUI) location informs the Receiving Professional where to refill Kanban Inventory as it is delivered. It will also provide the appropriate amounts to the Kanban Front and Back bins. During this process any visible Back Bins are re-positioned to make the Front Bins visible again.
Consolidated Vendor Agreement – Having a CVA is paramount in an effective Lean Campaign. The provides a foundation for automatic procurement of inventory at pre-arranged prices based with established re-order quantities. This involves negotiating with the Vendor so that you do not need to shop “prices” each time a purchase is made. The upside to the vendor is a commitment to get a majority of your business.
Lean Purchasing – A paperless procurement system to instantly convert a Kanban reorder signal into an electronic Purchase Order. Typically 80% of purchases will be Kanban Controlled items and with the increase of purchasing frequency from increased inventory turns, the purchasing department can maintain the additional work load without any impact on labor.
Lean Vendor Invoicing – With increased inventory turns, there is an increase of vendor invoices. The software used to generate invoicing is streamlined to calculate invoice totals and easily reconcile to Purchase Orders received. This minimizes most of the data entry involved in creating vendor invoices.
Lean Receiving– An efficient Bar Coded process to receive Kanban replenishments with POU put-away and Front Bin and Back Bin replenishment quantities.