AX2012 Lean Manufacturing

Doug BullaVice President of Business Development

Value Stream Map

Coil Steel

Purchase Receiving Dock

Event Kanban Per Unit

Sales Order

Request/Planned Dates

Total Quantity

Adjust Price(s

Configured Product

Sell Warehouse

Encore Assembly Process

Master Planning

Purchase Orders

Event Kanban Customer

Graphics Process

Meter Process

Event Kanban for Meter

Transfer Kanban forBezels

Event Kanban

Trigger Transfer

Graphics Supermarket

Meter Parts Supermarket

SuppliersEmpty Bins

Event Kanban for Graphics

Event Kanban

Paint Booth

Event Kanban for Paint

Sheet Metal Supermarket

Sheet Metal Process

Fixed Kanban for Sheet Metal Parts

Empty Bins

Encore Parts Supermarket

Plan for Every Part

Applications in Traditional MFGConsignment InventoryVMI ProgramsSub-ContractingDynamic Kitting

Consignment Inventory

ConsignedWarehouse

Picking Warehouse

Manufacturing Process

Withdraw From Consignment

Signal

Production Order

Routing

BOM’s – Pegged Supply

Process Instructions

Estimate Step

EDI – 852,861,867Milk Run

Pull Signal Via Email,Fax

Purchase Release Signal

Agreement

Quantity

Date

Create Purchase Release

Purchase Release

Any Period of Time

Total Quantity

Adjust Price(s)

Match to Invoice

EDI – 862Paper

FaxEmail

Vendor Invoice

Period of Time

Total Quantity

Adjust Price(s)

Match to Purchase Rel.

Match for Payment

EDI 810Paper

FaxEmail

VMI Programs

VMI WarehouseWarn Industries

Picking Warehouse

Transfer OrderBased on Master Plan, or

Withdrawal KanbanEDI – 852, 867,204,214

Sales Order Shipment

Date Consumed

Quantity Consumed

Relieve VMI Inventory

Create InvoiceInvoice

Any Period of Time

Total Quantity

Adjust Price(s)

Match to Payment

Trigger Replenishment

EDI – 867, 852, 850Bar Code Scanner

Empty Bin

Master PlanMin/Max,Empty Bin

Sub-Contracting

IEWC Wire Rod Inventory

EDI 943, 944, 947, 204, 214RF or Touchscreen

EDI 856 or 940, 945, 947, 204,214RF or Touchscreen

Wire Rod

Kanban for Contract Manufacturing

Purchase Release Signal

Agreement

Quantity

Date

Create Purchase Release for Value Add

Purchase Release

Any Period of Time

Total Quantity

Adjust Price(s)

Match to Invoice

Vendor Invoice

Period of Time

Total Quantity

Adjust Price(s)

Match to Purchase Rel.

Match for Payment

EDI 810 or 945Paper

FaxEmail

Event Transfer from Wire Rod Inventory

Manufacturing Process IEWC

Master Planning

Purchase Orders

Trigger Transfer

IEWC

Dynamics Kitting

Kitting

Manufacturing Process

Withdraw From Buffer Inventory

Signal

Contract Release

Quantity

Date

Sequence

RAN/KIT Number

Receive EDIANSI,EDIFACT,VDA, ODETTE

Ship Release

Quantity

Date

Sequence

RAN/KIT Number

EDI 866, 830 and/or 862 KIT/SequencingCustomer

Manufacture EventSignal

BufferOut_01

EDI 856,846,204,214

Produce to Order Pull from Buffer Inventory

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