Kanban implementation increases flexibility and reduces inventory levels

MRP / ERP

Just-in-time installation

Kanban implementation increased flexibility and reduced inventory levels

With the introduction of just-in-time (JIT) assembly of tool arms for changing the workpieces in CNC machining centers and the acquisition and production of the required components, assemblies and a Kanban system under SAP was introduced. In the implementation, it was without adjustment programming, reduced lead times, reduced inventories and high supply readiness to adjust optimally.

For the workpiece changer for CNC machining centers from Chiron tool arms are needed, their mounting on just-in-time manufacturing was changed. Image: Chiron

Chiron, the company manufactures CNC vertical machining centers, which are manufactured in series production, adapted by a modular system but also to individual tasks. The product range includes five-axis universal milling machines, machining centers, long-bed and single-or two-spindle machining centers with integrated workpiece changer. For the workpiece changer tool arms are needed, their mounting on just in time (JIT) should be changed. The aim of this change was to improve the delivery performance while reducing inventory levels.

Inventory reduction potential of 43% pre-determined

The issue of feasibility has been cleared by a pre-analysis data. This provided a potential inventory reduction of 43% of the value of existing stock to the start of the project. To change this Werkzeugarmproduktion to JIT, inventories have been shifted forward to the variant-forming component level before the tool arm assembly.

The aim was a card-Kanban with access to the SAP Kanban system without adaptation programming. The concept was basically non-SAP "normalized", but develops functionally optimized. Kanban following procedures should be used:

• event-driven kanban for the views of the tool arms (JIT assembly);
• Card kanban system for urgent spare part needs of the tool arms;
• Container Kanban system for pre-assembly of modules;
• Collective Kanban system for in-house production of components;
• Card Kanban and Kanban-container system for the integration of suppliers;
• 2-bin Kanban system and Umlagerungskanban for small parts and bulk materials.
  

Implement as the requirement that a collective-Kanban with traffic control in SAP was problematic here, because the SAP standard collection offers not to Kanban as a standalone function.

The benefits of collective kanbans with traffic control (Fig. 1) is a flexible in-house production. For only if the number of kanban container in the red zone, must be started with the production. Is the number of empty Kanban containers still in the yellow area, you can start the production. This flexibility gives the production area the opportunity, the timing and amount of subsequent delivery to determine. To interpret all production-related parameters such as container volume, number of parts per container, minimum and maximum batch sizes, lead, setup, production and transportation times and scrap quantities, production batch sizes of customers and so on were taken into account.