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Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Introduction to Tugger DeliveriesPrinciples of Milk Run
Marek Piatkowski – November 2016
Thinking win, Win, WIN
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
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 CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
Airport Baggage Train
Tugger
Factory Tugger
Factory Tugger
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Tugger Deliveries – Design Principles
Time based (regular schedule) - deliveries based on a regular schedule, “Milk Run”
Random based - deliveries based on a “as needed” signal
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Two Methods of Delivering Material
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Tugger Operating 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
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Tugger Operating Principles
All delivery routes must be well defined and standardized Point-of-Use (Parts Presentation at the Line) 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 and assembly lines or work cells
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Designing Tugger Deliveries
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
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Designing Tugger Deliveries
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
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Designing Tugger Deliveries
There are two ways of loading and unloading a Tugger Train:
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
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Delivery of Small Boxes
Delivery of Small Containers
Delivery of Small Containers
Delivery Train
Tugger Carts – small boxes
Tugger Carts – large containers
Tugger Carts – large containers
Tugger Carts – large containers
Delivery of Heavy Containers
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Delivery Route
17
18 19 20
N
A
C
1
2 3
4
- Drop Points
0
D
B
RHVLMAIL STOP
MAINT.MAIL STOP
MAINMAIL STOP
Standard Route Times: A-Shift
7:15 a.m.
9:15 a.m.
11:30 a.m.
1:30 p.m.
B-Shift
3:15 p.m.
5:15 p.m.
7:30 p.m.
9:30 p.m.
C-Shift
11:15 p.m.
1:15 a.m.
3:30 a.m.
5:30 a.m.
O
26 Drop Locations 16 Pickup Locations
Mail Route (A-Shift Only):
11:30 Route -->Pickup Outgoing Mail
1:30 Route -->Drop-Off Incoming Mail
Route Information
All of 12mm and 11mm Green Components
14
J
ENG.MAIL STOP
H
9
I
101112 G
25MFG. SERV.MAIL STOP
22
13
L
23
78
24F
M
6
21
K
DOCKMAIL STOP
START/FINISH
5
Milk Run Stops
Milk Run Stops
Milk Run Stops
# 6
FINAL 1FINAL 1
ALTERNATEURALTERNATEUR
DEPARTHORAIRES :
07:00 07:30 08:00 08:30 09:00 09:30 10:00 10:30 11:00 11:30 11:45 12:30 13:00 13:45 14:00 14:30 15:00 15:30 16:00 16:30 17:00 17:30 18:00 18:30 18:45 19:30 20:00 20:3021:00 21:30 22:00 22:30 23:00 23:30 23:4500:30 01:00 01:30 02:00 02:30 03:00 03:3004:00 04:30 05:00 05:30 05:45
ALTERNATEUR
Tugger Deliveries - Metalsa
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
Tugger Deliveries “Milk Run”
Thinking win, Win, WIN
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