Mixed Model Material Management


Category: SKU: MY-MMMM-MMMM-OT-001


A major component of a Mixed Model line is the design of the material delivery system. An even flow of materials to the line is the key to high operator productivity, optimum inventory investment, floor space reduction, and on-time delivery. The Mixed Model Material Management online course is an 18-lesson review of all of the key elements of a Lean material management system. It includes hands-on exercises, quizzes, and a variety of audits to begin improving your material delivery system right away.

We’ve organized the Mixed Model Material Management curriculum into short, manageable lessons to improve your learning and retention. Lessons contain videos, images, case studies, recordings, downloads, quizzes, and a glossary of Lean terminology.

Introduction to Flow Manufacturing: Curriculum

You will get familiar with the course interface, and review the main topics of this 17-lesson course.

In this lesson you will develop a deep understanding of the optimum material delivery workflow and strategy.

The surprising source of modern material flow systems.

Every individual item that will be managed, both purchased and manufactured, will be documented in detail in the PFEP database.

Your job as the designer of a material delivery system is to know which tool to use. Kanban is a general term that refers to a variety of different pull signals, which will be examined one-by-one.

Kanban means “signal”, and the supermarket strategy for managing inventory and overcoming imbalances is an essential element of a Lean material management strategy.

Kanban is not the only signaling method that will be used, and this lesson reviews to options available to a Material Flow designer.

One of the goals of Lean Material Flow is to balance material coverage (no shortages) with high inventory turns. In this lesson you will calculate optimum inventory levels for a variety of different items.

Material presentation is an integral part of optimum workstation design. In this lesson you will review basic objectives and examples, as well as look at some provocative new ways to deliver and present materials to an operator.

Physical storage of items, in a warehouse or supermarket, is a major consumer of space, working capital, and time. Physical stored needs to be design for optimum and efficient put-away and retrieval.

A Material Flow Designer will need to partner with Manufacturing Engineering to design supermarkets and item quantities to overcome time lost through changeovers on machine parts.
You will choose from a variety of Material Conveyance methods, from hand delivery to Automated Guidance Vehicles (AGVs).
The philosophy of “frequent trips and light loads” will be accomplished through the design of your delivery routes. The establishment of Standard Work for material delivery is also applied in this step.
The Lean Material Flow strategy puts a strong emphasis on container standardization. The integration of containerization strategies with internal Kanban systems and outside supplies will be understood.
Material Flow designers use a “roadmap” or checklist, for consistency and completeness. In this lesson you will learn the 10 Key Design Principles.
A Lean Material Flow system will continue to use computer systems for planning and inventory control, and high inventory accuracy is a must.
The material delivery system needs continuous vigilance and management. In this important lesson we will review the methods and practices needed to ensure that your system is on a path of continual improvement.
In this final lesson we will review the Material Management Acceptance Criteria, and offer some final suggestions for productive next steps.


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