Dynamic LEAN Shop Floor SMT Material Control Starting ONLY What You Can Finish

摘要

In high mix (250+ Assemblies) environments, ensuring small batches are delivered in a timely yet flexible manner without large levels of safety stock and WIP requires the very best of LEAN Manufacturing practices. Dynamic Process Control's (DPC) Material Reservation Manager (MRM) has been designed to provide the tools for major reductions in floor stock and the ability to manage production schedules to maximise utilisation and productivity in this highly dynamic environment. In line with the current need to dissect volumes into small (<100 unit) Kanban driven batches, using these tools can minimise losses from unplanned changeovers due to missing or un-locatable material. Any combination of Kanban and ERP/MRP driven order batches can be dynamically loaded automatically in real time. In this example the operators on each of 5 SMT lines perform 'what if s' on each batch. Tracking material reels, matrix trays and sticks loaded on SMT equipment or stored in line locations outside materials controlled storage, we can then check there is sufficient material available to complete the order. If insufficient material is available on the line but is available in material's storage, it is reserved, picked and transferred to the line in time for the orders scheduled start. Shortages preventing production are flagged and the order rescheduled. Using these tools can reduce waste and eliminate lost time waiting for parts that have been depleted or changing over due to those parts not being available. Every item of material outside of material stores is tracked as it is being used allowing for the application of material FIFO, the use of part used material before new and the real time enforcement of rules such as 'use by dates' and quarantines.