“Milk Run” Tugger Deliveries - Marek on Lean€œMilk Run” Tugger Deliveries Introduction Marek Piatkowski December 2010. Marek Piatkowski – FSP Consulting 2. Marek Piatkowski

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Marek Piatkowski – FSP Consulting

Materials StrategyMaterials Strategy

“Milk Run”“Milk Run”

Tugger Tugger DeliveriesDeliveries

IntroductionIntroduction

Marek Piatkowski

December 2010

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7

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Delivery Method – Design PrinciplesDelivery Method – Design Principles

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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

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.



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

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.



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

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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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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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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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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

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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

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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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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.

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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

[email protected]@rogers.com

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Documents

“Milk Run” Tugger Deliveries - Marek on Lean€œMilk Run” Tugger Deliveries Introduction Marek Piatkowski December 2010. Marek Piatkowski – FSP Consulting 2. Marek Piatkowski