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MRP, Lean Inventory Project – Where to Start?

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  • #45693

    Patrick
    Participant

    I work for a mid-sized manufacturer of highly engineered assemblies (high mix, mid to low volume).  We do some in-house manufacturing (machining of castings) and outsource the rest of the components from suppliers around the world.  In 2006, a number of internal improvement teams worked on ‘reducing inventory’ and made no progress.  Their approach based on some pareto analysis was to go after some of the major issues like supplier transitions and product phase outs and the results were minimal.
    I have been tasked with fixing the problem but I think it is more of a Lean project and I am very early in my lean training.  I have suggested we look at a specific manufacturing cell and work the problem front to back by looking at order process, throughput, lead times, downtime, quality defects, etc.  I don’t think our management is completely sold on the idea but we don’t really have anyone practicing true lean so they don’t really have a good baseline.  I see lots of wasted $’s on our shop floor (WIP $, low turning components, wasted time looking for parts).
    Sorry for the long introduction…  Any suggestions on where to get started.  I have a basic process map on each of the manufacturing areas.  Any assistance would be appreciated.

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    #149901

    Adam Bowden
    Participant

    If you want to bounce your ideas and plans off me please do so. A lean approach will certainly work but will only be sustainable if
    you set your plan of attack early on which will be based upon the
    business culture and needs.The Aerospace industry and alot of Industrial Engineering
    businesses are high mix low volume – Creating flow and “thowing
    the sacred MRP cow” out will come.Regards,Adam [email protected]

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    #149904

    EdG
    Participant

    Start out value stream mapping your product families.  It will make your wastes readily apparent.  Then start attacking those.

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    #149963

    Patrick
    Participant

    Thanks for the advice.  I’ll drop you a line.

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