Today’s Lean Manufacturing Challenges
–Culture Change—Leanmanufacturingisnotatechniqueoramethod,itisanentire
philosophyaboutmanufacturingthatcanbecounter-intuitive,generatingresistanceand
non-compliance.
–Deployability—Itisdifficulttodeploy/maintainleanprocessesandtechniquesacrosslarge,
dynamic,complexvaluestreams.
–Applicability—Traditionalleantechniquesweredevelopedforaspecificenvironment,
builtonassumptionsofstabilityandsimplicity.Innovationanddiscretionarerequiredto
adaptleanmethodologiestomorecomplex,dynamicenvironments.
–Responsiveness—Traditionalpullsystemsaregenerallyunresponsivetovolatiledemand.
–Mixed Mode Manufacturing—Isbecomingstandard,requiringmoreplanningsophistication
thanavailableintraditionalleanapplications.
–Diversification—Traditionalleansystemsgenerallyhandlediversityinproductmix
inefficiently,requiringinnovationandplanningautomationtoenablecompetitiveness.
–Planning—Traditionalleansystemsfocusmoreonexecutionthanplanning,makingthem
morereactiveandinefficientindynamicenvironments.Theabilitytoreplanefficientlyand
intelligentlyisakeyenablerincomplexenvironments.
Making Lean
Manufacturing Happen
–Culture Change—Doesyour
organizationunderstandand
acceptthebasictenetsoflean?
–Deployability—Canyourollout
andmaintainleanprocesses
acrossyourorganization?
–Applicability—Canyou
innovativelyapplylean
principleswithoutcompro-
misingprofitability?
–Responsiveness—Doyour
leanprocessesrespondquickly
toadynamicdemandsignal?
–Mixed Mode Planning—Can
youplanbothmake-to-stock
andconfigure/build-to-order?
–Diversification—Areyou
abletoefficientlyhandle
varietyandcomplexityin
yourproductmix?
–Assessment—Canyou
quicklydevelopalternative
plansandevaluateimpact
onkeymetrics?
If not...how can you make
lean manufacturing happen?
Figure 1
LLM Workflow
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i2 Product Sheet
i2LeanLIfecycleManagement
Lean Lifecycle Management
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i2 Product Sheet
i2LeanLIfecycleManagement
2
What is Lean Lifecycle Management?
LeanLifecycleManagementisacomprehensivesolutionspecificallydesignedtoenablelean
manufacturingdeploymentindynamic,complexsupplychains.LLMiscomprisedofdomain
expertise,aninnovativeapplicationthattightlyintegratesplanningandexecution,automating
numerousleanplanningfunctions,andindustry-specificleantraining.LLMenablesplanners,
operators,andsupervisorstocreate,evaluate,publish,andexecutepull-basedproduction
plansinchallengingproductionenvironments.
Benefits
Inventory Reduction—Typical Benefit: 15–30%
–Intelligentinventorybuffermanagement
–Supermarketkanbansizingbasedontruedemand
–Dateeffectivitytoreduceobsoletepartinventory
Supply Coordination—Typical Benefit: 10–20%
–Kanbanloopsizingbasedontruedemand
–Stablescheduletosuppliers
–Exceptionmanagementofschedule/
receiptdiscrepancies
Premium Freight Reduction—Typical Benefit: 50–75%
–Inventorycoveragesynchronizedtotruedemand
–Rapidre-planningtosynchronizesupplytodemand
–Earlywarningtomanageexceptions
Planner Productivity Improvement—Typical Benefit: 50%
–Managementbyvisibilityintoexceptions
–Rapidre-planningtosynchronizedemand
withsupply
–Scenariomanagementbycomparingvariousplans
Solution Differentiators
Level Planning and Scheduling
–Capacity/mix-leveledplanwithlotsizeand
setupoptimization
–Problemidentification,what-if,plan,andpublish
in1dashboard
Visual Interactive Execution Dashboards
–PacemakerPlanning,HeijunkaScheduling,
OperatorandSupervisorTaskList,Supplier
ReceivingDashboards
“Thereisalargeperformance
gapbetweencompanies
simplyusingLeantechniques
ontheshopfloorversusthose
thathavebuiltaculturebased
onLeanthinking.”Source: Aberdeen Group— March 2006:“The Lean Benchmark Report: Closing the Reality Gap”
Oftherespondentstoan
AberdeenGroupSurvey:
–67%useLeantechniques
sporadically
–87%haveLeanknowledge
infewindividuals
–93%relyonspreadsheets/
papersolutionstoperform
high-valuefunctions,such
aslinedesignandload
levelingproduction
Figure 2
Positioning LLM: When Does
it Make Sense?
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i2 Product Sheet
i2LeanLIfecycleManagement
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–Executiondatadrivingfocusedcontinuousimprovementrecommendations
–Designedforeffectiveexecution:“OneScreentoAction”
Value-Stream Control, Autonomy, and Flexibility
–Excel-likeformat,planneroverride,exception-basedworkflow
–Supportformultiplepullschemes
–Completemanagementofvaluestreammasterdata
Comprehensive Lean Deployment Methodology
–Rightmixofsupplychainandleanmanufacturingprocessandtechnologyexpertise
–Corecapabilitiestoimprovequalityofdemand,supply,allocation,andpromiseplanning
–Supplychainandshop-flooroperationsbestpractices
Key Capabilities
Role Base Dashboards—Live visibility into plans, key metrics, data
–Management—Keymetrics—historical/projected
–Pacemaker Planner—Create/publishlevelplan
–Heijunka Execution—Scheduleexecution/conformance
–Kanban Planning—Kanbanparametercalculation
–Operator—Supermarketworkcenterprioritizedjobs
–Receiving—Tracksupplierkanbanperformance
Value-Stream Data Management
–Save,retrieve,andmanageas-is
andfuturevaluestreamdata
–Continuoussynchronizationof
planningandexecutiondata
Lean System Design and Planning
–CalculateandanalyzeTakt-time,
cycletime,FGbuffers
–Calculatelevelingbuffer,forecast
errorbuffer,safetystock
–Inventorytargetsmayvaryweekly,overrideasdesired
Pacemaker Level Planning
–Createrepeatableplanineach
periodforMTS,BTO,ATOparts
–Enablesrepeatablesequencevia
attribute-basedchangeover
–Balancecapacity,targetinventory,
setupstooptimizeEPEI
Figure 3
Planning Dashboards
Figure 4
Interactive Execution
Dashboards
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11701LunaRoad
Dallas,Texas75234,USA
Phone1.877.926.9286
Webwww.i2.com
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i2 Product Sheet
i2LeanLIfecycleManagement
�
–“Excel-like”usability,planneroverride,andfastre-planning
–Considerproductionoffloading,resourcebalancing,calendarswithvariabletimes,
anddateeffectivity
–Buildahead,full,andpartialoffloading
–Scenariocomparisonforwhat-ifanalysis
–Enablescollaborativereviewandpublishingofplan
Pacemaker Heijunka scheduling and execution
–Real-timeHeijunkaboardenablesoperatorexecutionworkflow
–Scheduleinstandardpackquantitiesacrosspaceintervals
–Monitorpitchattainmentbycomparingplanvs.actual
–Escalationlevelstoreportmissedpitches
–Enablesplanattainmentdisciplinevianon-compliancecodes
–Suggestskaizenviahistoricalproductionnon-compliancedata
–Sort/aggregatebypartnumber,familiesset-uppreference
Kanban Planning
–Dynamicupdateofkanbandaysofcovervalues
–Supportsfixedtime/variablequantity,variabletime/fixedquantity
–Visual,exceptionreportingexposesloopsneedingattention
Kanban Management and Execution
–Supportskanban,CONWIP,andPOLCAsignalingtechniques
–OperatorDBshowspriorities,production/materialauthorizations
–Report/trackjobcompletionstatus
–Tracksupplierkanban:open,in-transit,in-stock,andconsumed
–Editloopsizes,add/removesupermarketkanban
Alerts and Exceptions
–Inventoryalerts:stock-out,under/overtarget
–Pulllooptoleranceexceptionviaopenloopthresholdvalues
–Takttimevs.cycletimeandcapacityviolation
–Pacemaker/supplyingoperationscapacityutilization
–Kanbantoleranceparametersforsupermarkets
Metrics and Analytics
–ComparescurrentandpastschedulesandKPIs
–Providesreal-timeleanmetricstodriveKaizen
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