A set quality threshold is exceeded and an alarm is set that first flashes a display screen then if it is not answered in a given period of time it may then send out several emails or ring a cell phone or pager, etc. When a corrective action for a production line problem is created a sequence is followed until the action is closed. Improved process control reduces cycle times and provides control where items go for their next step.
Things change; suppliers get added; new employees are hired; and new facilities are added to the mix. Over time, it is inevitable that a fresh approach to operational efficiency should be performed, with the payoff of identifying a couple of process improvements that can make an impact on your bottom line, as well as to positively impact your customers.
With the goal of eliminating waste, the following are five suggestions on how you might remove deficiencies that are having a negative impact on productivity and profitability. I challenge you to review these five key organizational standards as possible areas for improvement.
Even if just one works, it will help you to reduce warehouse, and even plant inefficiency, which will then result in improved asset management performance within your organization. The opportunity here is to avoid the need to do clean up, reconciliations, or any other extra work necessary to ensure the integrity and accuracy of the data is maintained.
The most common way to accomplish this objective is to focus on superior technology tools that can help to ensure data integrity, standardization of processes and meaningful audit capabilities. All of these components are critical not only within a warehouse environment, but also across as a cross-organizational effort to optimize the tracking of inventory and material throughput, within not only your own warehouse or plant, but out to the extended supply chain as well.
Better visibility into these operations will result in greater accuracy of the data collected, and a reduced need to do clean up later down the line. Many top-performing organizations realize significant benefits in terms of market competitiveness when they deploy advanced warehouse technology and reporting tools that privilege data governance.
Inventory Storage Management Solutions Today, most organizations include warehouse and inventory management within their operations, production or supply chain management functions.
One of the aims of supply chain management is to optimize inventory throughput by leveraging the value of real-time information concerning the status of inventory and storage bin utilization. Superior standards call for accurate awareness of inventory while it is in a warehouse.
Effective warehouse design, such as storage systems that provide ready visibility to Work-in-Process can be an effective tool to achieve superior standards. Vendors such as Quantum Storage offer Steel Shelving and other products that can assist in this realm.
Vendor Compliance Programs A vendor compliance program communicates to vendors exactly how you want their product to arrive. Your program should include specific labeling requirements, standard case quantities, advanced shipping notification standards, or any other policy that you believe will help your plant or factory to perform more consistently.
This strategy is even more paramount your operations are distributed across a multi-site environment. Standards for any effective vendor compliance program should be developed through a collaborative effort involving procurement as well as operational personnel.
Organizational Culture and Diversity Language barriers are expected to remain a problem for warehouse manages well into the foreseeable future. The International Warehouse Logistics Association IWLA discloses on its blog that logistics industry standards and best practices should involve deploying multilingual software and protocols that encourage managers to embrace diversity in the workplace.
The use of bar codes is one approach that can help to overcome the language barrier. As materials or Work in Process is received and scanned, these items can then be tracked and managed throughout the production process without risk of human error in typing in the wrong information as it arrives on a receiving dock.
Cross-Docking Superior logistics planning includes cross-docking wherever possible. Cross-docking is the practice of unloading materials from an incoming vehicle and immediately loading these same materials directly onto outbound vehicles with minimal or zero warehousing interval between.
Cross-docking is an ideal solution when product freshness is paramount. Cross-docking evolved out of a need to get perishable goods to market quickly.
This procedure is one of the key inclusions an organization can make to its portfolio of standards whose function is to drive manufacturing and distribution center improvements. Even if a Lean program has been implanted, the opportunity to find new areas for operational improvement likely still exists.Just-in-time (JIT) manufacturing, also known as just-in-time production or the Toyota Production System (TPS), is a methodology aimed primarily at reducing times within production system as well as response times from suppliers and to customers.
Its origin and development was in Japan, largely in the s and s and particularly at Toyota.
|Japanese Cultural Experience||For Tools in the M — Z Range, click here. The overall philosophy of Lean, i.|
|Improving Manufacturing Processes Through Lean Implementation | Quality Digest||Lean manufacturing is no different.|
|Lean tools for your business.||With varied products from medical to defense, electronics, transportation, consumer products and everything between, we have extensive track record in creating simple, cost effective solutions.|
|Shinka Management Lean Japan Tour - Kaizen Japan Training||Author Archive Reducing waste, implementing efficiency-promoting practices, and continuously improving operations are the main goals of lean manufacturing ideology.|
|Lean Manufacturing Tools, Techniques and Philosophy | Lean and Related Business Improvement Ideas||This section does not cite any sources. Please help improve this section by adding citations to reliable sources.|
[page needed] [disputed – discuss], [page needed. Lean Manufacturing Definition (s) Lean Manufacturing Definition (s) made simple: This glossary of lean manufacturing terms, whilst not exhaustive, will provide explanations to many of the terms used in your lean manufacturing training..
The definitions contained here may have slightly differing meanings, dependant upon the context in which they are used but as a general guide you will find. Worksmart Systems offers expertise in innovative and cost effective lean manufacturing and assembly with extensive experience creating simple solutions.
I would argue that SAFETY isn’t, on its own, a category of what I would want to go “Lean” in my warehouse. The above article is focused on how to remove waste, improve efficiency and reduce costs in the Warehouse not on what general best practices are. Want to see more? View the videos from the December Lean Japan Tour (Volvo Group), July Lean Japan Tour, April Lean Japan Tour, November Lean Tour, July Lean Japan Alumni Tour, April Lean Tour, November Lean Tour, July Lean Tour, May Lean Tour or the November Lean Tour..
To register download the brochure for our tours. Lean Consulting Case Studies. The proof is in on the bottom line! Results speak for themselves, so whether you are looking to solve issues around productivity, lead times, employee engagement or are just sick of firefighting then you too can find a better way.