Lean Execution Modules
Customer Kanban manages the Finished Goods (FG) replenishment. It provides an easier way to manage FG inventory by consolidating the customer demands and a better insight into customers’ demand patterns. This goes a long way in controlling the variances on the front end of the value chain. Customers also get good visibility into where their orders are at any time and can assess the performance of the plants. This collaboration may lead to reduction in overall lead times and reduce the precious FG inventory buffer.
The Internal Kanban module allows you to set up multiple work centers and associate consuming work centers with the supplying work centers. Any number of work centers can be created depending on how many areas need to be tracked.
The Lean Production module provides a visual cue to what is being produced at each work center, what is completed and which jobs are on hold and if so, why. The sequence of production can be customized based on several factors depending on the plant’s business process. It could be as simple as FIFO, or can be as complex as sequencing on several parameters like family, boring size, color or other product specs. Since the system knows the cycle time and setup time for each part, it can highlight whether the WC is over or under capacity for each day. The supervisor can reschedule it (move it to another day) or re-sequence it (change the priority) within a single day.
The Supplier Kanban module deals with the replenishment of raw materials between the plant (or warehouse) and external suppliers. The module allows planners/buyers to set Kanban sizing for the parts, visually monitor the ordering process, react to exception alerts and obtain metrics for continuous improvement. This module is collaborative in nature thereby engaging the buyers and suppliers to work toward a single goal—Just-In-Time replenishment. Everyone needs only a browser to access the application, and they can do it from anywhere in the world.
Schedule Based Replenishment (SBR)
SBR gives suppliers real-time visibility into forecasts and the ability to improve performance by responding to active orders faster. It provides buyers and suppliers with a single, integrated replenishment interface that shows the status for every order in the system—both Kanban and non-Kanban. The SBR system:
- Systematically publishes forecasts, planned orders and change orders based on demand changes.
- Automates and streamlines ordering processes.
- Provides suppliers with an environment to accept, make changes and collaborate in the purchase-order execution.
- Tracks orders with suppliers while they are in process and in transit.
- Provides suppliers with standardized shipping labels with barcodes, eliminating data entry during receiving.
- Consistently monitors supplier performance.
Lean Assessment Tool
It is important for organizations to determine where they are in their Lean journey. Even though Lean is overarching and spreads across the corporation for process changes and improvements, one area on which it has immediate impact is how the organization manages its inventory. The module not only highlights problem areas but also showcases the potential savings.