4.1. Synchronized parts supply
For this case, the manufacturer created 49 racks in which to
place the synchronized parts supply. The racks were designed to
hold the parts as a unit load without the need for a container, with
the parts either hanging using a hook or laying on the racks and
using the element of poka-yoke to avoid mistakes and encourage
the First In First Out (FIFO) concepts.
Fig. 2 shows the process flow for the synchronized parts supply
from the local suppliers to the manufacturer. The suppliers receive
the information for the WIP sequence from production planning
through the line status monitoring at the MES portal. Next, the
parts are prepared in the racking based on the sequence which
means that when the parts arrive at the receiving area in the manufacturer’s plant, the parts are already in sequence and are synchronized
with the assembly line.The system will calculate the required quantities of parts and
the quantities of parts for order. The information for the required
quantity of parts will appear in the supply form via the web portal
such that the Production Control Department in the temporary
storage area can supply parts to the supermarket area at the specific
time at the right place with the required quantity. In the
ordering flow, after the system generates the fixed delivery time
and estimates the time arrival for each part, the system will order
a specific time and submit the information to the suppliers or 3PL
by uploading the ordering format to the ERP. The suppliers view
the order on the web and print the order form as shown in
Fig. 5. The supplier will deliver the parts to the manufacturer
according to the quantity ordered at a specific time.
Many benefits are provided by the e-kanban system. Accurate
information can be obtained by avoiding the manual part ordering
operations that lead to human error. The information is also applied
as a web-based system with real-time data which makes it simpler
for the manufacturer and suppliers to monitor the parts ordering
and delivery processes. The system also reduces the job scope for
the shopping man and eliminates forms that must be filled out.