Download - Lean en France 6 ENST Presentation
Lean en France 6ENST Presentation
2006October, 6th
Eric Moreau
2006October, 6th
Lean & LogisticsStock Reduction Processes
Eric Moreau
3
Raw Material (Detailed)
3. ReduceLead Time
2. Control Lead Time
1. Understandyour stocks
Pareto
Flat storage FIFO
ABC Analysis
Visualization
Segmentation
Stocks in € or days
Nb of material shortage
4
Raw Materiel inventory segmentation
Stock needed between2 deliveries
Internal flow + supplier MPM
Safety stocks to covertransport risks
Stocks needed to covervariations of demand
5
Raw Material (Detailed)
3. ReduceLead Time
2. Control Lead Time
1. Understandyour stocks
Stocks in € or days
Nb of material shortage
Stocks in days
Pareto
Flat storage FIFO
Excel Software
ABC Analysis
Visualization
Segmentation
6
Detailed check neededat receiving
MPM RISK
Advanced shipmentNotice
Against Lead Time reduction !
Supplier triesto fill up truck
Suppliers paies logistics
DDP Deliveries
Supplier
MILK RUN very difficultto implement
demand => Supplier modifies it
MOI + Stocks
ERP Info (Fluctuation)
RM - Supply most frequent process
7
Supplier
Faurecia decideQuantity
& Lead Time
1st Manifest CheckSupplier
Target = 0 MPM
Receivingprocess issimplified
Less MOI
Faurecia Control
incomingprocessEX WORKS
Leveled demandtrough Manifest
Faurecia Control Lead Time
2nd Manifest checkTruck Driver
Target = 0 MPM
Less stocks
RM - New process to be implemented
Rule : when MPM is not ZERO , Truck can not leave supplier without agreement of Faurecia
8
Raw Material (Detailed)
% suppliers Ex Works
Nb of leveled suppliersManifestLISA
Ex WorksLeveling
3. ReduceLead Time
2. Control Lead Time
1. Understandyour stocks
Pareto
Flat storage FIFO
Excel Software
ABC Analysis
Visualization
Segmentation
Stocks in € or days
Nb of material shortage
Stocks in days
9
Pulversheim
Impact of suppliers leveling
Actual
Nb Leveled supplier
200522
30
9
12
20
7 7
12
1919
12
30
2,5
3,5 3,53,3
3,6 3,6
3,4
3,9
2,9 3,2 2,92,6
0
5
10
15
20
25
30
janv févr mars avr mai juin juil août sept oct nov déc0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
10
Crevin (Seating - JIT plant)
Impact of suppliers leveling
0
500
1000
1500
2000
2500
3000
3500
Janv Févr Mars Avr Mai Juin Juil Août Sept Oct Nov Déc
Mois
K€
Valeur de stock BOP usine
Start of levelling9 suppliers
45 % Sales
Safety stocks (holidays) 14 suppliers
70 % sales 21 Suppliers
96 % Sales
BOP STOCKS 2005
11
Raw Material (Detailed)
Nb deliveries / day
% suppliers Ex Works
Nb of leveled suppliers
Supplier MPM
Milk runs
Switch points
ManifestLISAAlert System
Ex WorksLevelingEducate suppliers
Increase frequency
Reduce transport time
3. ReduceLead Time
2. Control Lead Time
1. Understandyour stocks
Pareto
Flat storage FIFO
Excel Software
ABC Analysis
Visualization
Segmentation
Stocks in € or days
Nb of material shortage
Stocks in days
12
Switch point
Supplier
8h 8h 8h
Full
Empties
Full Full
EmptiesEmpties
13
Raw Material (Detailed)
Nb deliveries / dayLead Time + packaging CapexFrequency of Deliveries
% suppliers Ex Works
Nb of leveled suppliers
Supplier MPM
Milk runs
Switch points
Cross docks
MANIFESTLISAAlert System
Ex WorksLevelingEducate supplier
Increase frequency
Reduce transport timeConsolidate withother plant
3. ReduceLead Time
2. Control Lead Time
1. Understandyour stocks
Pareto
Flat storage FIFO
Excel Software
ABC Analysis
Visualization
Segmentation
Stocks in € or days
Nb of material shortage
Stocks in days
14
Stocks in days
MPMInternal
External
Stock reduction process (WIP, RM, FG)
PPM, Rework, scrap% of breakdownDays of stocks Tool change time
QR/QC7 Quality basicsTPMFix batch Kanban, SMED
Pool stockLevellingboardKanban
Absorb customerfluctuationsPull SystemSplit Stocks
Improve qualityImprove reliabilityReduce batch size everypart / every shift
WIP
FG