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PROBLEM

Operators had excessive inventory surrounding their workstations. In the assembly area, some parts had a 3 month supply at the line and were not being consumed FIFO. Such excessive inventory created safety hazards.

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Approach

The goal was to create a supermarket of purchased parts to pull inventory away from assembly, then deliver parts as needed Just In Time. We created a Value Stream Map to see the overall flow of purchased parts into the facility to the assembly area. A Plan for Every Part was created to figure out what parts were needed, where,
and quantity.

Using the gathered information, a Kanban system was established and a Tugger Route was able to deliver parts JIT.

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Results

• Pulled purchased parts away from assembly area
• Established a purchased parts supermarket in Receiving
• Reduced inventory
• Improved safety surrounding assembly
• Tugger Route delivering parts JIT

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