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W IE 141 Material Replenishment
W IE 141 Material Replenishment
Replenishment
IE Webinar
Work Measurement PFC
& Time Study
W-IE-141 Webinar
Rev-1.1
W-IE-113
MODULE CONTENT
1 Definition
5 Material Replenishment
Constraints
2 Objectives
Kanban
6
3 Material Management
4 Supermarket
8 Rack and Trolley Design
9 Summary
2
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OBJECTIVES
DEFINITION
Material Replenishment is the system of moving upstream material (from the warehouse) to downstream value add
processes (our workcells).
The purpose is to keep material flowing through our value stream to feed the manufacturing lines in order to meet our
customer demand.
Products (WIP)
Raw Material
Sub Assemblies
3
OBJECTIVES
OBJECTIVES
Material Replenishment
Warehouse Production Floor
Free up space for production Reduce Headcount Eliminate line stoppages and production
line downtimes
4
OBJECTIVES
MATERIAL REPLENISHMENT MANAGEMENT
2 Common Systems
Push System Pull System
Scheduled systematic controlled Replenishment material as the Workcell
ordering – regardless if Workcell needs requires it
it or not
Key principle of Lean
Every X
hours
5
OBJECTIVES
MATERIAL REPLENISHMENT MANAGEMENT
2 Common Systems
Push System Pull System
Warehouse
Warehouse When hit
min level
Supermarket
Workcell
Workcell
Every X
hours
When hit
min level
6
OBJECTIVES
MATERIAL REPLENISHMENT MANAGEMENT
Aim to design the most efficient & effective system that fits our needs!
7
MATERIAL REPLENISHMENT MANAGEMENT
Supermarket
SMT for WIP Workcells
Must align to our customer demand, production, and material replenishment system!
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PUBLIC | ©Jabil Inc. 2019. All Rights Reserved..
OBJECTIVES
MATERIAL REPLENISHMENT MANAGEMENT
Material Handler is required to replenish the material even the Frequent replenishment needed if the product has short cycle times and/or
material usage is low large parts
Require more space for material storage on the production Need a system of communication to replenish the material, risk of slow
floor replenishment and production interruption
High inventory
Need to create detail schedule for every operation and job
order
Missed/Forget the schedule due to no signals
Difficult to control on First in First Out
9
OBJECTIVES
MATERIAL REPLENISHMENT MANAGEMENT
Supermarkets
1
Every X
Warehouse hours
Non Common
Workcell
2 When hit
Every X min level
Non Common
hours
3
When hit Common
min level
10
OBJECTIVES
MATERIAL REPLENISHMENT MANAGEMENT
Supermarkets
Warehouse 1 Workcell
Non Common
11
OBJECTIVES
SUPERMARKET
What is a Supermarket?
A Supermarket is not just inventory & WIP.
It is controlled inventory & organized WIP
according to a workcell’s demand consumption.
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SUPERMARKET
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PUBLIC | ©Jabil Inc. 2019. All Rights Reserved..
OBJECTIVES
SUPERMARKET
Supermarket Size:
Demand Rate = 40 / hour
Demand Rate (material units per hour): Rate at which inventory is
Replenishment Time = 12 hours consumed.
Replenishment Time: The initial interval time required to replenish material.
Minimum Inventory Level (MIL) = 20% Minimum Inventory Level (MIL%): The percent of inventory that exists
for material handler to kit and deliver the material and to protect against
Total number of parts/unit = 15
downtime.
Bin Capacity = 100
%)
= 40 * 12 * (1 + 20%)
= 576 (for one part)
= 8,640
Bin Quantity =
87 bins 15
OBJECTIVES
SUPERMARKET
Workstation Supermarket
16
OBJECTIVES
MATERIAL REPLENISHMENT CONSTRAINTS
Constraints
Large Parts Constraint
When it’s required to assemble large parts, the cycle time is usually longer, thus, it is not
possible to store material at the workstations.
To reduce waste:
1. Setup the Supermarket near the assembly stations
2. Allocate a space for the huge material nearby
17
OBJECTIVES
KANBAN
What is a Kanban?
Kanban in Material Replenishment is a tool to help to manage the supermarket and the
workstation.
A Kanban is the method of when to replenish the supermarket or workstation via use of a
visual/digital indicator. It can be traffic light system, milk run delivery method, etc, or a
combination of these systems.
Kanban method
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OBJECTIVES
KANBAN
Collect
empty bin
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OBJECTIVES
KANBAN
The previous examples are manually managed, thus, there could be a risk of communication error that could
lead to line stoppages and downtimes.
Target ID
Location
Time
Warehouse
Warehouse
SMT Workcell
Supermarket
Supermarket
for Workcell Materials
(OLFS)
21
OBJECTIVES
LAYOUT AND MATERIAL FLOW
Supermarket
Cell 2 Cons:
Assembly 4 Assembly 3 Assembly 2 Assembly 1
Supermarket
If we must load from the front of the
workstations, then we need to factor in the
time lost for production due to material
replenishment.
Assembly 4 Assembly 3 Assembly 2 Assembly 1
Cell 2
Rac
Rac
Rac
k
k
23
OBJECTIVES
RACK AND TROLLEY DESIGN
Design
Gravity flow rack, design for good ergonomics and Multiple bin size trolleys for material
fast-speed replenishment replenishment at one go
The design is based on the Site’s needs, and engineers need to select or design
the right rack and trolley.
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OBJECTIVES
RACK AND TROLLEY DESIGN
Workstation design that allow to replenish and collect empty bin from the back of
the workstation with gravity rack build in
There is a side rack for large material or for a workstation that not able to
replenish from the back 25
OBJECTIVES
SUMMARY
26
SUMMARY
Material
Replenishment
Reduce Cost
Flow
Schedule
Better Material
Flow Eliminate
downtime
Effective Inventory
Reduce Headcount
Control
Eliminate Non-Value
Improve efficiency & added steps
Free up space
reduce fatigues
27
PUBLIC | ©Jabil Inc. 2019. All Rights Reserved..
THANKS
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