Levelled production without peaks
The DCIx Lean system is a tool for the implementation of lean production. Lean production is more than just printed kanban cards. The foundation stone is a smooth plan without significant fluctuations. Where changes in customer requirements are reflected as far as the production, it always means additional costs. Having a levelled, smooth plan means grouping similar products into groups, spacing customer requirements evenly in time and regularly changing groups. Final assemblies, in particular, are planned in this manner. A levelled assembly plan needs to be verified from the point of view of parts availability, kanban circuits need to be checked and recalculated for pre-productions or replenishment of storebins from the supermarket.
In addition, some parts are prepared simultanously with assembly. Pre-assembly, warehouses or even suppliers receive an update for the preparation of parts, specified time in advance prior to its assembly point. In the event there is an unexpected production downtime and a change of plan, a process similar to checking the feasibility of a plan takes place. Plan, check, order parts, update and evaluate.
ico Solution Possibilities of DCIx Lean
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Levelled weekly production plan – assembly in product groups
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Capacity balancing of assembly lines
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Planning boards for manual plan modifications
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Heijunka – a detailed breakdown of the daily plan for each assembly line’s starting point, for Pacemaker
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Synchronisation of pre-assembly – a detailed daily plan for pre-assembly
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Operative changes to the daily plan related to parts call-offs and batch pre-production
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Component availability checking
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Generation of call-offs for synchronised deliveries of parts from stock, from an external warehouse, from suppliers
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Generation of call-offs for batch pre-production
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Calculation and update of kanban circuits
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Production booking
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Visualisation on displays at the assembly line, in pre-assembly, in the warehouse, in pre-production
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Evaluation of plan changes
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Evaluation of plan versus reality
ico_Competitive Advantages of DCIx Lean
- These days you don’t have many options:
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Excel as a tool that can do everything
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Own development ordered internally or externally
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Or DCIx Lean
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Fast plan creation – in the order of seconds
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As simple and clear as in Excel
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Back reporting of data
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Integration with the DCIx WMS warehouse system
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Integration with the DCIx Portal portal for electronic kanban with suppliers for synchronised deliveries
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…therefore easily taken corrective action sufficiently in advance
