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1
Marek Piatkowski – FSP Consulting
Materials StrategyMaterials Strategy
“Milk Run”“Milk Run”
Tugger Tugger DeliveriesDeliveries
IntroductionIntroduction
Marek Piatkowski
December 2010
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
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Marek Piatkowski – FSP Consulting
Delivery Method – Design PrinciplesDelivery Method – Design Principles
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Marek Piatkowski – FSP Consulting
Why Change?Why Change?
Original Condition Tugger Condition
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
Sat
Lift
Assy
Short
Plg
Assy
Short
Plg
Assy
12 mm
Assy
2 hr
921
Lift
Assy
T-Car
Lift
Assy
2 hr2 hr
2 hr
T-Car
Plg.
Assy
ACI
Lift
Assy
ACI
Lift
Assy
ACI
Plg
Assy
Short
Assy
2 hr
2 hr
2 hr
2 hr
2 hr 2 hr 2 hr 2 hr 2 hr 2 hr 2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
3 day
3 day
3 day
3 day
842
Plg
Asst
Sat
Plg
Assy
846
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Plg
Assy
Cevt.
Ball
Storage
“D”
Rec.
Insp
“A”
952
Spring
“B”
972
Brutor
Area
“C”
11 mm
Assy
DAH
Assy
2 hr
2 hr
2 hr
2 carts
800 of matl.
1 hr 45 min in a tour
Proposed value stream small components to assy. lines
12 mm
Assy
I
921
Lift
Assy
T-Car
Lift
Assy
II
I
T-Car
Plg.
Assy
ACI
Lift
Assy
ACI
Lift
Assy
ACI
Plg
Assy
Short
Assy
I
I
I
I
I I I I I I I
I
I
I
I
I
I
I
I
I
I
842
Plg
Asst
Sat
Plg
Assy
846
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
Sat
Lift
Assy
Short
Plg
Assy
Short
Plg
Assy
Cevt.
Ball
Storage
“D”
Rec.
Insp
“A”
952
Spring
“B”
972
Brutor
Area
“C”
11 mm
Assy
DAH
Assy
I
I
Supermarket
Roller
Sup.
DAH
Supl.
Rec. Insp
Penny
Vendor
Sup.
12 mm
11 mm
Sup.
T-Car
Janet
ACI
Sup.
GF
Manuf.
Services
Original Condition Tugger Condition
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
Sat
Lift
Assy
Short
Plg
Assy
Short
Plg
Assy
12 mm
Assy
2 hr
921
Lift
Assy
T-Car
Lift
Assy
2 hr2 hr
2 hr
T-Car
Plg.
Assy
ACI
Lift
Assy
ACI
Lift
Assy
ACI
Plg
Assy
Short
Assy
2 hr
2 hr
2 hr
2 hr
2 hr 2 hr 2 hr 2 hr 2 hr 2 hr 2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
3 day
3 day
3 day
3 day
842
Plg
Asst
Sat
Plg
Assy
846
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Plg
Assy
Cevt.
Ball
Storage
“D”
Rec.
Insp
“A”
952
Spring
“B”
972
Brutor
Area
“C”
11 mm
Assy
DAH
Assy
2 hr
2 hr
2 hr
2 carts
800 of matl.
1 hr 45 min in a tour
Proposed value stream small components to assy. lines
12 mm
Assy
I
921
Lift
Assy
T-Car
Lift
Assy
II
I
T-Car
Plg.
Assy
ACI
Lift
Assy
ACI
Lift
Assy
ACI
Plg
Assy
Short
Assy
I
I
I
I
I I I I I I I
I
I
I
I
I
I
I
I
I
I
842
Plg
Asst
Sat
Plg
Assy
846
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
Sat
Lift
Assy
Short
Plg
Assy
Short
Plg
Assy
Cevt.
Ball
Storage
“D”
Rec.
Insp
“A”
952
Spring
“B”
972
Brutor
Area
“C”
11 mm
Assy
DAH
Assy
I
I
Supermarket
Roller
Sup.
DAH
Supl.
Rec. Insp
Penny
Vendor
Sup.
12 mm
11 mm
Sup.
T-Car
Janet
ACI
Sup.
GF
Manuf.
Services
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
Sat
Lift
Assy
Short
Plg
Assy
Short
Plg
Assy
12 mm
Assy
2 hr
921
Lift
Assy
T-Car
Lift
Assy
2 hr2 hr
2 hr
T-Car
Plg.
Assy
ACI
Lift
Assy
ACI
Lift
Assy
ACI
Plg
Assy
Short
Assy
2 hr
2 hr
2 hr
2 hr
2 hr 2 hr 2 hr 2 hr 2 hr 2 hr 2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
3 day
3 day
3 day
3 day
842
Plg
Asst
Sat
Plg
Assy
846
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Plg
Assy
Cevt.
Ball
Storage
“D”
Rec.
Insp
“A”
952
Spring
“B”
972
Brutor
Area
“C”
11 mm
Assy
DAH
Assy
2 hr
2 hr
2 hr
2 carts
800 of matl.
1 hr 45 min in a tour
Proposed value stream small components to assy. lines
12 mm
Assy
I
921
Lift
Assy
T-Car
Lift
Assy
II
I
T-Car
Plg.
Assy
ACI
Lift
Assy
ACI
Lift
Assy
ACI
Plg
Assy
Short
Assy
I
I
I
I
I I I I I I I
I
I
I
I
I
I
I
I
I
I
842
Plg
Asst
Sat
Plg
Assy
846
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Plg
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
842
Lift
Assy
Sat
Lift
Assy
Short
Plg
Assy
Short
Plg
Assy
Cevt.
Ball
Storage
“D”
Rec.
Insp
“A”
952
Spring
“B”
972
Brutor
Area
“C”
11 mm
Assy
DAH
Assy
I
I
Supermarket
Roller
Sup.
DAH
Supl.
Rec. Insp
Penny
Vendor
Sup.
12 mm
11 mm
Sup.
T-Car
Janet
ACI
Sup.
GF
Manuf.
Services
13
Marek Piatkowski – FSP Consulting
Two Methods of Delivering MaterialTwo Methods of Delivering Material
1. Fixed Time
Random quantity delivery
2. Fixed quantity
Random time delivery
Flow Rack
Trigger
point
15min.
WIP for feeding
the machine
Signal lamp
Kanban Post
WK
B
WKB
Kanban Post
WK
B
On a set and timed route e.g. 45
minutes the material handler will
pick up the Kanban cards and
deliver product line side
WKB
In response to inventory decreasing
below the trigger point, the material
handler brings a fixed quantity e.g. two
boxes to the line
45 minute
repeating loop
Store
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Marek Piatkowski – FSP Consulting
Tugger Deliveries Tugger Deliveries -- Design PrinciplesDesign PrinciplesTugger Deliveries Tugger Deliveries -- Design PrinciplesDesign Principles
Random based - deliveries
based on a “as needed” signal
Two types of material delivery systems:
Time based (regular schedule)
- deliveries based on a regular
schedule, “Milk Run”
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Marek Piatkowski – FSP Consulting
Creating information flow - DeliveryCreating information flow - Delivery
Decide on a delivery method:
Time based “Milk Run” or random deliveries
Small container vs bulk container
Standard Work for Material Handlers
Identify frequency of deliveries
What signal to use
Decide on the “Point-of-Use” inventory levels
How much inventory to keep at the line. Use PFEP.
How much inventory to deliver each time
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Marek Piatkowski – FSP Consulting
Creating material flow - DeliveryCreating material flow - Delivery
Identify a delivery route
Material pick up and delivery points
List of material to delivery at every point
Map out the delivery route
Disposal of returnable containers and trash
Verify readiness:
of each part for the delivery
of delivery equipment
of each pick up point – Warehouse/Supermarket
of each delivery point – Line/Work Cell
17
Marek Piatkowski – FSP Consulting
Operating PrinciplesOperating Principles
All deliveries and material handling conducted only by designated people
from the Material Handling department – NOT production operators
Empty or returnable containers are picked up by the Tugger and delivered
to the warehouse - NOT to the Supermarket.
Delivery Kanban cards must be collected on regular basis and returned to
the Supermarket.
All material taken from the Supermarket must be delivered and left at the
Line. No material is returned to the Supermarket. “Take only what you
need”.
No Kanban (signal) – no delivery
18
Marek Piatkowski – FSP Consulting
Operating Principles (Con’t)Operating Principles (Con’t)
All delivery routes must be well defined and standardized
Point-of-Use racks and WIP markets to be located along main delivery
routes to allow timely delivery system
Point-of-Use storage locations well designed and located near main
delivery routes
All parts and components delivered to the line must be operators ready –
boxes open, all packaging material removed
All material must be stored on designated racks. No material to be stored
on the floor or in the isles
An attempt should be made to minimize Forklift traffic between warehouse An attempt should be made to minimize Forklift traffic between warehouse
and assembly lines or work cellsand assembly lines or work cells
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Marek Piatkowski – FSP Consulting
Tugger Deliveries Tugger Deliveries -- Design PrinciplesDesign PrinciplesTugger Deliveries Tugger Deliveries -- Design PrinciplesDesign Principles
There are two ways of loading and unloading Tugger:
Coupled (1 Operator)
Tugger driver loads the carts in the Supermarket and delivers parts
to the point-of-use.
De-Coupled (2 Operators)
One Operator is Tugger driver only delivering parts
Another Operator is a Supermarket Attendant who loads the carts
in the Supermarket.
20
Marek Piatkowski – FSP Consulting
Lean Transformation SolutionsLean Transformation Solutions
Marek PiatkowskiMarek Piatkowski
F.S.PF.S.P. Consulting Inc.. Consulting Inc.
VM: 416VM: 416--235235--26312631
Cell: 248Cell: 248--207207--04160416
Marek.Piatkowski@rogers.comMarek.Piatkowski@rogers.com
www.TWIwww.TWI--Network.comNetwork.com
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