kanban ballast mexico
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Acuity Business SystemAcuity Business System
Mexico CityBallast Kaizen - Kanban
Ballast Supermarket & Kanban
January 25 – 26, 2007
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Team Members- Samuel Juarez, Francisco Lopez, Antonio Cruz,
Eduardo Jimenez, Andy Scott, Tom Winenger, Randy Crothers
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Standard Pack – 1 layer per pallet
• Plus– Smaller buffer qnty.
– Easy material handling
– Increased safety
– Smaller replenish qnty.
– Reduced number of pallets purchased in Ohio
• Delta– Increased cost per
ballast ($0.25 USD) on average
– More spaced required in supermarket racks
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New Shipping Rules – S.O.P.• Load weight is the limiting factor for number of
ballasts per load• Ballasts can ship 3 pallets high (1 layer per pallet)• Trucks will always leave Mexico City to Newark
on Monday and Wednesday.• Additional trucks will be used on Thursday and/or
Friday if a full load is required through kanban signal and ballasts are available.
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Standard Operating Procedures
• Supermarket Buffer Review
• Mexico City Truck Schedule
• Scheduling
• Supermarket
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Mexico City Supermarket Layout
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Current State Scheduling-MRP
Firm Ship
Schedule
Forecasted
Requirements
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Plan For Every Part
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Future State Scheduling-Pull
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Buffer Levels• Mexico CityInventory increase from 2-5 days on hand for 21 supermarket ballasts
Inventory stay same for 40 Build to Ship ballasts
• NewarkInventory increase from 7-10 days on hand for 40 Build to Ship ballasts
Inventory decrease from 10-7 days on hand for 21 supermarket ballasts
• UticaInventory decrease from 3-1 days on hand for 61 Mexico City ballasts
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Current Production Scheduling
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Future Production Scheduling
M
T
W
R
F
Kanban Post
Supermarket
Production Schedule Board
Scheduling Department
Production Line
Finished Assembly
Take to the
supermarket
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Report Card
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