Lean Manufacturing Training Guide

242 Pages·2016·6.48 MB·English

QAD Enterprise Applications
Enterprise Edition
Training Guide
QAD Lean Manufacturing
70-3217-2016EE
QAD 2016 Enterprise Edition
April 2016
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Contact the appropriate companies for more information regarding trademarks and registration.
Copyright © 2016 by QAD Inc.
LeanManufacturing_TG_v2016EE.pdf/mdf
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Contents
QAD Lean Manufacturing 
Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Credit and Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
QAD Learning Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
QAD Document Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
QAD Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1 Lean Manufacturing Concepts. . . . . . . . . . . . . . . . . . . . . .5
Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
What is Lean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fundamental Concepts of Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Goals of Lean Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
House of Toyota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Important Tools of Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Prerequisites Lean Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Value Stream Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Small Valves Value Stream - Current State . . . . . . . . . . . . . . . . . . . . . . 23
Small Valves Value Stream - Future State . . . . . . . . . . . . . . . . . . . . . . 24
Takt Time and How It Is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
EPEI and How It Is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
What is a Pull System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
How does a Pull System work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pull System mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
One Card or Two Card Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
What are the typical Visual Displays supporting Pull . . . . . . . . . . . . . . . . . . . . 44
Example 1: Hijunka Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Example 2: Load Assembly Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Example 3: Kanban Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ii Training Guide — Lean Manufacturing
Chapter 2 Basic Functions of QAD Lean . . . . . . . . . . . . . . . . . . . . .51
Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Relationship with Core QAD Enterprise Applications . . . . . . . . . . . . . . . . . . . . 53
Value Stream Modeling in QAD Lean – Quick Setup . . . . . . . . . . . . . . . . . . . . 55
Practice Sessions Value Stream Map . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Basic Menu Functions for Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Kanban Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Kanban Control - Transaction Control . . . . . . . . . . . . . . . . . . . . . . . . . 62
Kanban Control (Transaction Event Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Kanban Item Master Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Supermarket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Manufacturing Replenishment Sources: Process Maintenance . . . . . . . 68
Kanban Process Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Supplier Replenishment Sources: Supplier Maintenance . . . . . . . . . . . 73
Inventory Replenishment Sources: Supermarket Maintenance . . . . . . . 74
Kanban Loops: Kanban Master Maintenance and Kanban Master Copy 75
Kanban Master Maintenance, FIFO Lane Data . . . . . . . . . . . . . . . . . . . 77
FIFO Lane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Kanban Master Maintenance, Supermarket Item Detail . . . . . . . . . . . . 79
Kanban Master Maintenance, Card Tracking Control . . . . . . . . . . . . . . . . . . . . 80
Kanban Master Maintenance, Dispatch Options . . . . . . . . . . . . . . . . . . 83
Kanban Master Maintenance, Kanban Transaction Control . . . . . . . . . 84
Kanban Master Maintenance / Kanban Master Copy . . . . . . . . . . . . . . 85
Kanban Management and Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Functions for Creating, Printing, Updating... . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Create, print, and re-print cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Kanban Card Create . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Kanban Card Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Kanban Multi-Card Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Kanban Multi-Card Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Kanban Card Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Kanban Transactions, Status Updates... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Kanban Transactions and Basic Inventory Updating . . . . . . . . . . . . . . 100
Consume-Fill Cycle (Replenishment Cards) . . . . . . . . . . . . . . . . . . . . 102
Consume-Fill Cycle (Withdrawal Cards) . . . . . . . . . . . . . . . . . . . . . . 103
Kanban Consume / Post Transaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Kanban History and Inventory History . . . . . . . . . . . . . . . . . . . . . . . . 106
Kanban Drill Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Dispatching Functions in QAD Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Kanban Dispatch List Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Kanban Loop Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Kanban Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Contents iii
Kanban Planning and Loop Sizing in QAD Lean . . . . . . . . . . . . . . . . . . . . . . . 117
Kanban Transaction Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Loop Sizing Alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Where Average Demand Is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Demand Calculation Template Maintenance . . . . . . . . . . . . . . . . . . . . 123
Demand Calculation Template Update . . . . . . . . . . . . . . . . . . . . . . . . 124
Assigning Templates to Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Running the Average Demand Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Average Demand Calculation Report . . . . . . . . . . . . . . . . . . . . . . . . . 127
Safety Stock Calculations and Templates . . . . . . . . . . . . . . . . . . . . . . 128
Peak Demand and Safety Stock Calculations . . . . . . . . . . . . . . . . . . . 129
Kanban Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Selection for Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Kanban Workbench Process Master Data . . . . . . . . . . . . . . . . . . . . . . 133
Kanban Workbench Process Detail, Sizing, Analyst Data . . . . . . . . . 135
Saw Tooth Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Leveling in QAD Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Leveling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
QAD Lean Takt Time Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Selection for Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Major Tabs and Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Level Mix Workbench Level Volume and Calendar . . . . . . . . . . . . . . 147
Level Mix Workbench Level Volume and Calendar, First and All Shifts 149
Level Mix Workbench First Shift Leveled Schedule . . . . . . . . . . . . . 150
Supermarket Workbench Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Major Tabs and Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Integration with Flow Scheduling and MPS . . . . . . . . . . . . . . . . . . . . 156
Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Chapter 3 Advanced Functions of QAD Lean . . . . . . . . . . . . . . . .159
Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Value Stream Modeling in QAD Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Kanban Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Kanban Control - Transaction Control . . . . . . . . . . . . . . . . . . . . . . . . 165
Kanban Transaction Event Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Additional Kanban Master Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Kanban Master Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Kanban Master Maintenance FIFO Lane Detail . . . . . . . . . . . . . . . . . 172
Kanban Master Maintenance Supermarket Item Detail . . . . . . . . . . . . 173
Kanban Master Maintenance Card Tracking Control . . . . . . . . . . . . . 175
Replenishment Card Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Move Card Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Kanban Master Maintenance Card Tracking Control . . . . . . . . . . . . . 180
iv Training Guide — Lean Manufacturing
Kanban Master Maintenance Card Despatch Options . . . . . . . . . . . . . 183
Kanban Master Maintenance Transaction Control . . . . . . . . . . . . . . . 185
Replenishment Card Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Move Card Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Basic Process Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Basic Process Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Basic Process Calculations Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Routing Roll-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Process Item Operation Roll-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Process Item Operation Roll-Up Audit Report . . . . . . . . . . . . . . . . . . 199
Calendar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Process Shift Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Kanban Planning and Loop Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Kanban Management and Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Additional Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Historical Buffer Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Methods for Loop Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Kanban Master Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Historical Buffer Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Inventory validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Inventory Validation Report Selection . . . . . . . . . . . . . . . . . . . . . . . . 213
Inventory Validation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Missing kanbans (lost cards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Missing Kanbans Report Selection Criteria . . . . . . . . . . . . . . . . . . . . . 216
Missing Kanbans Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Wrap Up / Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Appendix A Reading Material on Lean Manufacturing . . . . . . . . . . .219
Reading Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Appendix B Study Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Study Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Answers to Study Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Product Information Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
QAD Lean Manufacturing
Change Summary
The following table summarizes significant differences between this document and the last
published version.
Date/Version Description Reference
April 2016/v2016 EE Rebranded for QAD 2016 EE, added link to Preface --
April 2015/v2015 EE Rebranded for QAD 2015 EE --
March 2014/v2014 SE_EE Rebranded for QAD 2014 SE_EE --
September 2013/v2013.1 SE_EE Rebranded for QAD 2013.1 SE_EE --
March 2013/v2013 SE_EE Rebranded for QAD 2013 SE_EE --
September 2012/v2012.1 SE_EE Rebranded for QAD 2012.1 SE_EE --
March 2012/v2012 SE_EE Rebranded for QAD 2012 SE_EE --
September 2011/v2011.1 SE_EE Rebranded for QAD 2011.1 SE_EE --
vi Training Guide — Lean Manufacturing
About This Course
2 Training Guide — Lean Manufacturing
Course Description
QAD designed this course to cover the basics principles of Lean Manufacturing and preparing to
implement Lean Manufacturing in QAD Enterprise Applications.
The course includes:
• An introduction to fundamental concepts of Lean Manufacturing
• An overview of basic functionality of QAD Lean
• An overview of some advanced functionality of QAD Lean
• Instructions on how to set up the Lean functionality
• Instructions on how to operate the Lean functionality
• References to other QAD materials, such as on-line help
• Study Questions (for student practice of key concepts and processes)
Course Objectives
In this course you learn how to:
• Identify some fundamental concepts of Lean Manufacturing
• Set up the basic functions for Lean in QAD Enterprise Applications
• Set up some advanced functions for Lean in QAD Enterprise Applications
• Use Lean Manufacturing in QAD Enterprise Applications
Audience
• Implementation consultants
• Members of implementation teams
• Operators
Prerequisites
• Initial QAD Enterprise Applications Setup training course
• Basic knowledge of:
• Theory of Lean Manufacturing
• QAD Enterprise Applications as it is used in the business
• Working knowledge of the manufacturing industry in general
Note Students that are unfamiliar with QAD Enterprise Applications should read User Guide:
Introduction to QAD Enterprise Applications before attending this class.
Course Credit and Scheduling
This course is valid for 12 credit hours and is typically taught in two days.
Questions? Visit community.qad.com