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MANAGING SYSTEMATIC PRODUCTION “Working managers, not managed workers,” is the way of the future UNDESTANDING DRUM – BUFFER - ROPE

Replenishment buffer management

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Page 1: Replenishment buffer management

MANAGING SYSTEMATIC PRODUCTION

“Working managers, not managed workers,”

is the way of the future

UNDESTANDING DRUM – BUFFER - ROPE

Page 2: Replenishment buffer management

DRUM: THE WEAKEST LINK ( PERIOD )

THE SHOP CAN ONLY GET SO MANY LABOR HOURS THROUGH THE PAINT BOOTH IN A DAY OR WEEK.

WE TRY TO STUFF A MARSHMELLOW IN A PIGGY BANK EVERY DAY !

DON’T WE?

SAY YOUR PAINT BOOTH IS YOUR PIGGY BANK / DRUM

THIS IS CALLED THE DRUM:

THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.

Page 3: Replenishment buffer management

• WE THE COMPANY WILL NOW LEARN TO COORDINATE EVERY THING ELSE AROUND

THIS FIXED PLACE.

•WE DO SO BY FIXING OUR SYSTEMS “NAIL THEM DOWN” IN ONE PLACE OF MAXIMUM

LEVERAGE AT THE CONSTRAINT.

Page 4: Replenishment buffer management

FIXING OUR SYSTEMS “NAIL THEM DOWN”

GATE DRUM BUFFER WIP DRUM SHIPPING

BUFFER

What is gate control?Understanding Replenishment BufferWhat is the drum buffer?Understanding the drumWhat is the shipping gate?

How do we Rope / tie it all together

Page 5: Replenishment buffer management

WHAT IS GATE CONTROL ?• Gate control allows Constant Work-In-Process, and designates a control strategy that limits the total number of labor hours allowed into the system at the same time. •The hours are released as they are processed at the consumption rate of the beat of the drum until they wind up in the last buffer as finished goods.

GATEDRUM

BUFFER WIP DRUM SHIPPING BUFFER

LABOR HRS. ARE RELEASED FROM

THE REPLENISHMENT

BUFFER

Page 6: Replenishment buffer management

Understanding Replenishment Buffer

•Replenishment Buffer management is a control mechanism. The idea behind it can be summarized in the following steps.

•Use the Replenishment Buffer to release labor hours as they are processed at the consumption rate of the drum.

AFTER1 Disassemble the vehicle , identified parts and labor

necessary to repair the vehicle.2 Verified parts price and availability, Order parts and place

vehicle into the staging area.3 Verified parts by mirror match parts,

4 kit repair for production.

Page 7: Replenishment buffer management

WHAT IS THE DRUM BUFFER ?• ALL OF THE WORK IN PROCESS BETWEEN THE GATE AND THE DRUM CONSTITUTES THE DRUM BUFFER.

• ALL OF THEWIP PRIOR TO COMPLETION CONSTITUTES THE SHIPPING BUFFER.

GATE

DRUM BUFFER WIP

DRUM SHIPPING BUFFER

Page 8: Replenishment buffer management

UNDESTANDING DRUM•DRUM: THE WEAKEST LINK IS THE RATE LIMITING STEP.

•THE DRUM BEATS OUT THE PRODUCTION RATE FOR THE WHOLE SYSTEM.

GATE DRUM BUFFER WIP

DRUM

SHIPPING BUFFER

Page 9: Replenishment buffer management

WHAT IS THE SHIPPING GATE ? •SHIPPING GATE IS DISCRIBED AS FOLLOWED:

• REASSEMBLY OF THE VEHICLE

• DETAIL

• QUALITY INSPECTION OF FINAL PRODUCT

GATE DRUM BUFFER WIP DRUM

SHIPPING BUFFER

Page 10: Replenishment buffer management

SYSTEMATIC PRODUCTION VIEW

GATEDRUM

BUFFER WIP

DRUM SHIPPING BUFFER

REPLENISHMENT BUFFER

STATE FARM

AIGGEICO

Replenishment buffer Replenishment buffer management is key to management is key to

systemic warehousing and systemic warehousing and distributiondistribution

Page 11: Replenishment buffer management

SYSTEMATIC PRODUCTION VIEW

STATE FARM

AIGGEICO

REPAIR WORK COMES IN TO YOUR SHOP WE WILL CALL THIS YOUR PIPE LINE OR FUNNEL

Page 12: Replenishment buffer management

1 Disassemble the vehicle , identified parts and labor necessary to repair the vehicle.

2 Verified parts price and availability, Order parts and place vehicle into the staging area REPLENISHMENT BUFFER

3 Verified parts by mirror match parts, 4 kit repair for production.

Page 13: Replenishment buffer management

Gate control allows Constant Work-In-Process, and designates a control strategy that limits the total number of labor hours allowed into the system at the same time. The hours are released as they are processed at the consumption rate of the beat of the drum until they wind up in the last buffer as finished goods

ALL OF THE WIP BETWEEN THE GATE AND THE DRUM

CONSTITUTES THE DRUM BUFFER.

Page 14: Replenishment buffer management

DRUM: THE WEAKEST LINK IS THE RATE LIMITING STEP.

THE DRUM BEATS OUT THE PRODUCTION RATE FOR THE

WHOLE SYSTEM.

IN THE BODY SHOP THE DRUM IS THE PAINT BOOTH. WE ARE LIMITED TO HOW MANY UNITS OR HRS CYCLE THOUGH IT A

DAY OR WEEK.

THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE

SYSTEM CAN WORK.

Page 15: Replenishment buffer management

SHIPPING BUFFER IS DISCRIBED AS FOLLOWED:

1 REASAMBLY OF THE VEHICLE

2 DETAIL

3 QUALITY INSPECTION OF FINAL PRODUCT

SHIPPING BUFFER

Page 16: Replenishment buffer management

Thank you for giving me the opportunity to train your company in understanding

Systematic production. Now that you understand the process we can now find your capacity and work on improving your through- put and reduce cycle time.

PRESENTED BY.

RANDY S FERRESE SR 824 BLUEBIRD CIRCLE

MAYS LANDING ,NJ [email protected]

609 553 4244