Even though the benefits of the lean production are very clear, the implementation work of such a system is very hard. Besides the training, the culture changes, value-stream reassessment and the adoption of JIT practices are normally much more difficult than it seems. Spreadsheets and manual processes are outlined during the implementation of the early pilots, but as the processes take place in the whole plant, these initial controls show to be insufficient.
The Drummer LEAN was developed to speed up the planning process, allowing quick answers to changes in the market conditions. The Drummer LEAN uses information related to stock level targets, backlog and capacity availability at the work centers to calculate the production volumes needed to replenish the stocks. After that, using a leveling algorithm, the system loads these production needs on the work centers, showing where each item should be produced, in what quantities and best production sequences.
Once checked by the user, the leveled schedule is sent to the shop floor via printed paper or an electronic Heijunka box.
As the factory team goes implementing improvements on the production processes (setup time reductions, etc), the Drummer LEAN goes constantly considering these new standards in its calculations.
Some functionalities of Drummer LEAN:
Generation of Leveled Production Schedules (Heijunka)
Based on the information regarding backlog, supermarket size and cycle time at production cells, the Drummer LEAN generates leveled production schedules, with reduced lot sizes and in accordance with the plant availability.
Finished-Goods Inventory Management
Through daily reviews, the Drummer LEAN projects the stock levels, indicating occasional material shortages and allowing a reassessment of the production schedule before releasing it to production.
Scenarios
The LEAN module generates all schedules using independent scenarios that can be quickly modified. As a result, conditions like backlog changes, overtime or machine breakdowns could be easily simulated to see their impact on the shop floor.
Some benefits achieved with Drummer LEAN:
Overtime Work Reduction
Production schedules leveled and adherent to the demand profile allow early identification and solution for the occasional capacity problems.
Operation / Transport Costs Reduction
The best planning process leads to a more stabilized production schedules, reducing the number of urgent orders to be expedited.
Work-in-Process Reduction
The fast and frequent replenishment of the items allows the company to reduce the inventories (finished and semi-finished goods) with no risk of having lack of products to customer.
Reduction in the efforts to Manage the Supply Chain
The production schedules are generated more easily and fast, creating an agile link between sales and purchasing.
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