Level and lean logistics
SEAMLESSLY LINKING WAREHOUSE AND PRODUCTION OPERATIONS
When a leading appliance manufacturer wanted to improve warehousing and logistics for their production plant in Czech Republic, they found Sumisho Global Logistics Europe had the all the expertise they needed. We were also able to meet their high environmental standards.
OUR SOLUTION
Working from warehouse facilities just five minutes from the production plant we put together a powerful lean and leveled logistics solution that resulted in cost, time and space savings for the company.
Our solution was a unique combination of three processes, blended together to create a powerful system that can work in almost any manufacturing industry:
HEIJUNKA - LEVELED PROCESSES
We have achieved a constant, uninterrupted delivery loop of parts to the assembly line through:
- Fixed time windows for parts delivery to the warehouse
- Three shift system over 24 hours
- Lean manufacturing operations
Every 80 minutes just the right parts are delivered at just the right time throughout each 24 hour day to enable the production line to produce just the right number of products to meet their customer demand.
Hyoujyunka - standardised operation procedure
Our standardised operation process means everyone at the warehouse knows exactly what they have to do and when they have to do it - including quantity and quality checks. This is essential to maintain a high level of lean logistics and production.
Doukika - synchronised logistics with production line
This is a replenishment system that ensures that only the parts needed to replace those that have been used are delivered to the warehouse and to the production line.
We use KANBAN cards (label with barcode) and KANBAN electronic data to ensure smooth, level and lean logistics across all delivery, dispatch and warehousing processes. Our processes have to be smooth and fast to provide a seamless link with the production line.
RESULTS AND BENEFITS
With leveled processes throughout, the warehouse is seamlessly inked to operations at the production plant. A constant delivery loop enables production lines to run smoothly without stoppages and all unnecessary wastage has been removed through optimised efficiency across all operations.
ON THE PRODUCTION LINE;
With just a leveled quantity of parts needed for each timed window of production, only a minimum amount of stock from local and global suppliers needs to be kept at the production plant at any one time. Other improvements include:
- Savings in cost, time and space
- Parts delivery now synchronized with production
- Reduced wait times and increased production
- Assembly line space maximised
- Production stability - No parts shortage therefore No production line stoppages
- More flexible, rapid response to changing customer demands
- Improved information management
- Company free to concentrate on priorities like production and design
AT THE WAREHOUSE;
- Cost, time and space savings
- Efficient, time-fixed shuttle operation to plant
- Improvements in packing, unloading and loading
- Reduced inventory and overhead costs
- More accurate inventory
- Improved quality management
- Better information management
- Less waste and scrap - kinder to the environment
With leveled, lean logistics in place, procedures at our Czech warehouse work like the best quality clockwork. We actively propose new ideas that add value to the customer's future business and through continuous improvement they can achieve enhanced lean logistics operations across their entire supply chain.
And with continuous improvement and KPI management - we are hoping to see leaner logistics spread across the entire supply chain.
These kinds of results are possible in most manufacturing companies. If you would like to discuss how we can do the same for you, get in touch and we will get back to you as soon as we can.