Lean Manufacturing Requires Supplier Replenishment

Lean manufacturing principles require a variety of inventory replenishment methods, including: schedule-based replenishment, discrete POs, min/max, consignment and VMI (vendor-managed inventory) replenishment methods. With supplier replenishment, manufacturers can drive replenishment from production schedules, publish forecasts to suppliers, and automate purchase order releases and receipts through a collaborative Internet portal.

Vendor Manged Inventory

Lean Manufacturing Concept

One key to efficiency is organization.  To help achieve this, The BoxMaker employs the concept of 7S:

Lean Manufacturing 7S

The results of implementation of 7S at BoxMaker include:

• Increased productivity
• Minimized waste
• Created a safe environment
• Increased morale
• Made training easier
• Increased teamwork

1. Sort: The easiest way to do this is to take everything out of the area, be it a production machine, an office, or even just a desk. Throw away any unused or unneeded items. Any items that are used infrequently (weekly or less) should be stored elsewhere. Rarely used, but still valuable, items can be put into storage.
2. Set In Order: All that should remain are those items that are used on a regular basis. Place those items back in locations that allow easy access. It is often very useful to label the locations these items are placed, so any user always knows were to return them after use.
3. Shine: This step involves insuring the area is kept as clean and clutter free as possible. Place trash and recycle bins close to areas that generate them. Ensure cleaning supplies are available in the area they are used most frequently. Keep aisles, rows, and/or desktops clear of unnecessary paperwork or debris. Clean equipment runs more efficiently, and lasts longer.
4. Standardize: Create repeatable standards that can be applied to more than just a single area or machine. It is
   
   
   useful to have someone regularly audit the areas or machines to ensure compliance.
5. Sustain: If all of the above efforts have been accomplished, it is vital to Sustain them. Support must come from management to allow time and resources for activities that support the 7S efforts of the teams or individuals involved. Employees must be encouraged and rewarded for their accomplishments in maintaining the 7S and understanding and applying the philosophy.
6. Spirit: This aspect is concerned with employees taking ownership, moving with purpose, and working together.
7. Safety: Although increased Safety is a byproduct of sorting, setting in order, and shining, it is also a philosophy and a way of seeing the environment. It could be as simple as taking an extra few seconds to pick up the scrap on the floor that might trip someone, or get caught in a piece of equipment.