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Lean Manufacturing
Enhancements
Part 1: SAP as a Lean Manufacturing Enabler
Part 2: Lean Manufacturing Enhancements
Part 1:
SAP as Lean
Manufacturing Enabler
Key Drivers and Business Strategies
How does SAP Enable Lean?
Manufacturing Strategies
Production to customer demand or based upon consumption
Shifting to single-piece-flow approach
Poka yoke (mistake-proofing)
Visual management
Kanban
Event and exception based processes
Organizational Strategies
Jidoka: operators empowered to stop line if there is an issue
Kaizen: continuous improvement
SAP AG 2006, Lean Manufacturing Developments ERP 2005, Jutta Wesemann-Ruzicka
Source:
AMR Research: East Meets West Lean
Manufacturing and ERP Are a Better Fit Than
You Think, October 2005
Recent evidence [...] uncovered that automotive manufacturers that are backing
their Lean efforts with an SAP platform are not only outperforming automotive
companies that have chosen Oracle, they are even better equipped to beat the
best, with automotive SAP customers outranking even the Best in Class for
manufacturing cycle time.
Maura Buxton, Aberdeen Group,
Automotive Industry Leads the Lean Supply Chain Charge with SAP Solutions, August 2006
South Africa
PT ASTRA
SIEMENSVDO
Part1:
SAP as Lean
Manufacturing Enabler
Key Drivers and Business Strategies
How does SAP Enable Lean?
Kanban
In-house movement, stock
transfers, and external procurement
Mixed-Mode Manufacturing:
- Make-to-Order Manufacturing
- Repetitive Manufacturing
Order-less production
- Flow Manufacturing Techniques
Preventive/Predictive Maintenance
Line Design
Sequence of events
Operational method sheets
Capacity line balancing
Quality Management
Statistical Process Control
Takt calculations
xMII
Backflush
Indicate component
quantity used for each
task
Drawings or graphical
representations are displayed
for each workstation
Planning Strategy
Planning Board
Part 2:
Lean Manufacturing
Enhancements
Benefits:
Provides the same information as the graphical board in a tabular display
Easy to configure, easy to use
Extensible to display additional system and customer-specific fields
Sophisticated print function
Can be displayed in web-based user interfaces (Portal)
Part 2:
Lean Manufacturing
Enhancements
Kanban Alerting
New alerts supported in the Kanban process:
1.
2.
3.
4.
Benefits:
-
Part 2:
Lean Manufacturing
Enhancements
Source
Material
l
Ful
Full
l
Ful
RF Gate
Empty
Kanban
(with RFID Tag)
Reduced
labor costs
Reduced
Part 2:
Lean Manufacturing
Enhancements
In-house Production
with Kanban (current):
mat
mat
mat
Operation 1
Operation 2
Operation 3
Supply Area
mat1
Storage
Location
0001
Storage
Location
0002
Storage
Location
0003
Component
mat1
Routing
Operation 1
Operation 2
RP 1
mat1
mat1
Operation 3
RP2
RP3
Final backflush
In-house Production
with Reporting Point
Kanban (new):
mat
mat
mat
Operation 1
Operation 2
Operation 3
Storage
Location
0002
Storage
Location
0001
Storage
Location
0003
Component
mat1
Routing
Operation 1
CC 1
mat1
mat1
Operation 2
Operation 3
RP 1
RP2
RP3
SA 1
SA 2
SA 3
CC 2
CC 3 Final backflush
Benefits:
Visibility and reduction of WIP
Assemblies are only produced when needed and in the quantity needed
Avoiding rework
Elimination of waste
Simplified and flexible production process
Part 2:
Lean Manufacturing
Enhancements
Material B
Material C
M
Material A
Leveling production volume
Material B
Material C
Material A
Leveling product mix
Material B
Material C
Material A
Material B
30 PC
20 PC
Material C
60 PC
Material A
10 PC
Material B
5 PC
Material C
20 PC
Material A
Material B
Material C
Material D
Material E
Material F
Requirement situation
of a shift or day
Heijunka: Sequencing
/Leveling of semifinished goods
Heijunka Leveling/Sequencing
Several tools and functions already in the SAP portfolio to support
Leveling/Sequencing:
Tools and functions for demand leveling:
SOP
(mySAP ERP)
Demand
Model
(mySAP ERP)
Demand
MRP
Tabular
Capacity
Sequence
Heijunka Leveling/Sequencing
Enhancements leverage key features and functions of mySAP ERP
to support Lean Manufacturing processes:
Pull
Order-less
Takt-based
Repetitive
Manufacturing (REM)
Kanban
Sequence
Planning
Part 2:
Lean Manufacturing
Enhancements
Your Turn!
Q&A
Jutta Wesemann-Ruzicka
Solution Manager
Jutta.Wesemann-Ruzicka@sap.com
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