Analysis of lean manufacturing at all levels
the benefits of lean manufacturing are obvious: build on demand, small batch production, and use Kanban management to simplify execution procedures. However, it is not easy to select production management software and its suppliers to support lean manufacturing
since lean manufacturing (in a broad sense) introduces intelligent production and quality analysis, not just Kanban based pull production system, it greatly increases the complexity. Even pull production based on Kanban has many aspects. Moreover, ERP, enterprise lean, and factory automation software suppliers are playing the card of lean manufacturing. Many enterprises regard manufacturing execution system (MES) in lean manufacturing as an important role
Julie Fraser, head of industry direction information consulting company in Massachusetts, said, "we have a lot of doubts." she said that ERP suppliers have made long-term efforts to support lean manufacturing. Manufacturing execution system is often used in lean manufacturing and six sigma. Factory intelligent software plays an important role in troubleshooting machine faults
Angus palm company of the United States produces protective devices for car equipment. It is beginning to adopt Kanban based lean system provided by demand stream company in its Tennessee factory to realize automated lean manufacturing. Rusty Coleman, material manager of Angus palm, believes that the system will be helpful to enterprises with multiple factory workshops
coleman said that increasing the automation and instant visibility of Kanban execution in lean manufacturing is one of its main advantages. Another alternative term is that when there is no lean manufacturing software in the endurance limit, the material manager is busy looking at the card to find information to supplement raw materials at any time, although he uses the Kanban card
with demand streams' products and comprehensive data sets, Coleman said: "the whole query work has been completely eliminated. When an operation is completed, I and others in the warehouse have a clear view of what is happening on the production line."
he said that another major advantage comes from the core engine of dynamic kanban. As lean manufacturing practitioners know, it enables manufacturing enterprises to produce or move materials within the factory in a timely manner, or arrange suppliers to supply materials in a timely manner. Originally, because there was no software to calculate the intricate Kanban, lean manufacturers had to make do with spreadsheet software
coleman said: "dynamic Kanban is far better than any excellent tabulation software. It will recalculate the requirements at every point in your lean manufacturing environment, and will display the manufacturing or purchase instructions only when the real requirements occur."
demand stream solution will be integrated with Angus palm's fourth shift ERP system. The latter is from SoftBrands and is a sister enterprise of demand stream. According to Coleman, this integration has improved the turnover efficiency of small batch materials in lean manufacturing in the ERP environment
integration with ERP
in Angus palm, the integration with ERP keeps the enterprise's transactions updated at all times, without using ERP to distribute materials or cutting orders every time a "plastic restriction order" is reduced to a "plastic sales order" step on the kanban. Coleman said, "with demand stream, we can record all the information we need while reducing the production volume."Ianachterkirch, partner of demand stream, explained that the basic engine of the system tries to convert a supplementary signal into an ERP purchase order. He said: "when a company introduces dynamic Kanban management, some lean manufacturing operations will encounter difficulties, but Kanban can never be combined with the inventory system. If you can't combine the two, your indirect costs will increase because you have to do everything twice."
the industry's view of it use in lean manufacturing is changing. John Richardson, CEO of Cimnet, a manufacturing execution system supplier, said: "many enterprises have mixed traditional order manufacturing and lean manufacturing transportation lines or downstream operations. This phenomenon is very common. Manufacturers need an appropriate system that can manage both at the same time."
richardson said that compared with the first prevalence of lean concept, other reasons why lean manufacturing based on it technology is increasingly accepted are that today's system has become more modular and configurable, and has better performance in communicating data with supply chain partners. "Most companies that do business with us want them to be able to collect data."
richardson said that data collection points need to be well defined and limited. Some data can be linked to the machine or controller through the interface to get the best collection results - but few manufacturers oppose lean manufacturing or it support today. Richardson said: "we no longer need to fight that kind of concept war."Tom buffo, director of QAD company, an enterprise product management software supplier, said that the company has a full set of lean production modules required for Kanban based pull production, including Kanban calculation, portfolio analysis and load reduction functions. He said that in the one year since the lean module was put into the market in the autumn of 2002, 80 companies have adopted the solution
buffo says that more lean manufacturers realize that they need a system that can not only implement lean manufacturing, but also collect information such as ideal production batch, product synthesis, production distance and time - for example, a calculation function that can synchronize lean manufacturing with demand. He said that these tools can properly set up and adjust the lean production line when necessary. "In lean manufacturing, it is difficult to expand in multiple work units, production lines or factories with a purely manual approach."
the role of MES
MES suppliers have different abilities to support piece flow and Kanban, but most MES solutions are excellent at collecting detailed execution data and quality related data. Fraser of industry direction said: "from the perspective of quality assurance, it is a general trend to use manufacturing execution system to support lean manufacturing. The manufacturing execution system can not only conduct analysis, but also guide electronic operations and command and dispatch. At that time, he was an 18-year-old student of Aerospace Engineering Department."
fraser said that a lean manufacturing enterprise is likely to use Kanban and procedure sheet to replace the progress and operation guide, but even a pure lean manufacturing organization "still needs the latest data on grass-roots production. When you have the current data in electronic form, you are confident to push them to the next link on time in May 2017."
MES can create the data needed for quality analysis and production line process improvement. Richardson believes that when implementing lean manufacturing, enterprises will pay close attention to testing - such as overall equipment efficiency (OEE) - especially when the overall equipment efficiency is abnormal and it is possible to quickly interrupt the lean manufacturing process
richardson said that the factelligence solution of Cimnet supports no order Kanban, and also extends its XML based supply chain connection module to enable it to pass lean replenishment instructions to suppliers. "To effectively implement lean manufacturing, enterprises need to understand the lack of materials or other problems outside the production line in real time and respond. But at the same time, lean manufacturing is not just about what happens in the four walls of the plant - it is about communicating with your suppliers.