supermarket design - marek on lean · pdf file03.09.2012 · 1...
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Supermarket Design Principles of Supermarket Marek Piatkowski May 2012
Introduction - Marek Piatkowski
Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario
from 1987-1994
TPS/Lean Transformation Consulting - since 1994
Professional Affiliations
TWI Network John Shook, Founder
Lean Enterprise Institute (LEI) Jim Womack
Lean Enterprise Academy (LEA) Daniel Jones
LEI Poland Tomasz Koch, President
Lean Transformation Solutions, Toronto, Canada
www.TWI-Network.com
Supermarkets Future State Objectives
One Purchased Parts Supermarket near Receiving
Small WIP Mini-Markets at Point of Use
One Finished Goods Supermarket near Shipping
WIP Mini-Markets located along main delivery aisles to allow timely delivery of parts
Visual management in place address locations, min/max levels identified, parts shortage indicators, inventory controlled by Kanban cards
All ergonomic and safety rules followed
Who designs Supermarkets?
Design Team
Industrial Engineering Manufacturing
Materials Management
Design Considerations
Concepts
Layout
Categorization
Storage / Racking
Addressing
Stock Rotation
Couple/De-couple Tugging
Rightsizing / Repacking
Information Flow System
Visual Controls
Enablers
Materials Organization
Location / Layout
PFEP Plan-for-Every-Part
Standard Work
WPO Work Place Organization
Receiving Window Compliance
Escalation Plans
There are several basic activities that need to be understood in order to develop a material movement/supermarket plan
Design Principle # 1
All parts, materials and components must be delivered to and stored in single centralized warehouse locations called Supermarkets
Supermarket Design Principle # 1
Insert picture of plant here.Storage
Storage
Storage
Storage
Storage
Storage
Storage
Storage
Storage
Storage
Insert picture of plant here.Storage
Storage
Storage
Storage
Storage
Storage
Storage
Storage
Storage
Storage
Current State
IM-11 IM-9 IM-7 IM-5 IM-3 IM-1
IM-12 IM-10 IM-8 IM-6 IM-4 IM-2
Paint
Booth
DC-1
DC-2
MC-1
MC-2
Receiving
Dock
Shipping
Dock
Legend
Cell #3 Cell #2 Cell #1
Assembly Cell
IM Injection MoldingDC
Die CastMC
Machining Center
Inventory Location
Cell #6 Cell #5 Cell #4
PBPaint Booth
Value stream area
Finished GoodsStorage
Value stream inventory
PurchaseParts
PaintedParts
MoldedParts
Value Stream Market
Open Space
Open Space
Molded
Open Space
IM-11 IM-9 IM-7 IM-5 IM-3 IM-1
IM-12 IM-10 IM-8 IM-6 IM-4 IM-2
Paint
Booth
DC-1
DC-2
MC-1
MC-2
Receiving
Dock
Shipping
Dock
Legend
Cell #3 Cell #2 Cell #1Cell #3 Cell #2 Cell #1
Assembly Cell
IM Injection MoldingDC
Die CastMC
Machining Center
Inventory Location
Cell #6 Cell #5 Cell #4Cell #6 Cell #5 Cell #4
PBPaint Booth
Value stream area
Finished GoodsStorage
Value stream inventory
PurchaseParts
PaintedParts
MoldedParts
Value Stream Market
Open Space
Open Space
Molded
Open Space
Supermarket Design Principle # 1
Current State Layout
IM-11 IM-9 IM-7 IM-5 IM-3 IM-1
IM-12 IM-10 IM-8 IM-6 IM-4 IM-2
Paint
Booth
DC-1
DC-2
MC-1
MC-2
Receiving
Dock
Shipping Dock
Legend
Finished Goods
WIP - Paint WIP - Molded WIP - Die Cast
Purchase Parts
Raw Material
Assembly Cell
Resin store for molding
Raw ingot area for die cast area
Painted product store
Purchased parts store
Molded Parts (non painted)
Die cast / machined parts
Finished Goods Storage Area
Overflow area
Aisle Way
IM
DC
MC
Injection Molding
Die Casting
Machining
Cell #2 Cell #1
Cell #5
Cell #3 Cell #4
Cell #6 Reserved Reserved Open
Open
Open
WA Washer
WA
Supermarket Design Principle # 1
Future State Layout
Supermarket Design at Donnelly
Start: 9:50 Stop: 21:00
Supermarket Design Principle # 1
Supermarket Layout
Supermarket layout must optimize Man/Machine/Material flow
Material - overflow, safety stock, normal, stock rotation, parts utilization, cardboard, empty containers
Man /Machine - minimize walk patterns (shopping), minimize mixing of Tugger (Milk Run) and forklift traffic, create one-way streets, information flow management
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8
9
1 2 3 4 5 6 7 8 9
Stocking Aisle
Stocking Aisle
Picking Aisle
Picking Aisle Traffic Flow
Traffic Flow
Supermarket Design Principle # 1
Design Principle # 2
All parts, materials and components must be grouped into some sort of logical fashion:
Either by family type, frequency of use, destination or suppliers
Supermarket Design Principle # 2
Design Principle # 3
Each part (container) must have a unique, designated, well identified storage location and address
Supermarket Design Principle # 3
Bad Good
Duplicate Storage Address
8 16 20 28 32 36
3 7 11 154 198 27
2 6 14 22 26 30 34
25 29 33 N4
N3
N2
N1
1
1 2 3 4 5
24
6 8 7 9
1311333332
12 4
A1
D
C
B
A
D
C
B
A
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
This part
numbers
address is D10
This part numbers
address is C5
This part numbers
address is C3 This part numbers
address i B2
Supermarket Design Principle # 3
Supermarket Addressing System
Storage Address System
Level Indicator
Location Indicator
Supermarket Design Principle # 3
Storage Address Labels Supermarket Design Principle # 3
Rack Labeling System Supermarket Design Principle # 3
Supermarket Design Principle # 4
All boxes and containers stored in the Supermarket must be Line or Customer Ready:
meaning right size and weight
100% Quality acceptable
any re-packing, to make boxes Customer Ready must be done in a centralized location outside the Supermarket.
Design Principle # 4
Bad Good
Supermarket Design Principle # 4
Repacking - Not acceptable
Repacking
Supermarket Design Principle # 4
Repacking
Single Box Flow Rack
Advantages:
Maximum utilization of storage space
Disadvantages:
Double handling of boxes
Safety / Ergonomics
Best application:
Low volume consumption
Small / light boxes
Full
Skid
Individual Boxes -
Hand loaded
Full skids stored
on upper levels
Rollers
Full
Skid
Fork Truck
Supermarket Design - Racks
Single Box Flow Rack Supermarket Design - Racks
Single Box Flow Rack Supermarket Design - Racks
Bulk Flow Racks
Advantages:
Elimination of unnecessary double handling of boxes (loading and unloading the rack)
Disadvantages:
Not the best utilization of floor space
Best application:
High volume demand
FullSkid
Full
Skid
Open skids stored
on a floor level
Full skids stored
on upper levels
Rollers
Full
Skid
Full
Skid
Full
Skid
Fork Truck
Supermarket Design - Racks
Supermarket Design - Racks
Bulk Flow Racks
Supermarket Design - Racks
Bulk Flow Racks
Bulk Shelf Storage
Advantages:
Elimination of double handling of boxes
Disadvantages:
Material Handler (Tugger) and Forklift wo