arrangement for dynamic lean replenishment and methods therefor
TRANSCRIPT
-
8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
1/17
US 20080215180A1
1 9 ) United S t a t e s
1 2 ) Patent Application Publication 1 0 )
P u b .
N o . : US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
Kota
4 3 )
P u b .
D a t e : S e p . 4 ,
2008
5 4 )
7 6 )
2 1 )
2 2 )
5 1 )
ARRANGEMENTFORDYNAMIC LEAN
REPLENISHMENT
AND
METHODS
THEREFOR
I n v e n t o r :
Rao
o t a ,
C u p e r ‘ t i n o , CA
U
)
C o r r e s p o n d e n c e
A d d r e s s :
IPSG, P . C .
P . O .
BOX 00640
SAN
OSE,
CA 5170
A p p l .
N o . :
F i l e d :
1 1 / 6 8 1 , 7 1 8
Mar. , 2007
P u b l i c a t i o n
C l a s s i ? c a t i o n
I n t . C l .
G06F
7/00
2 0 0 6 . 0 1 )
( 5 2 ) US. l .
. . . . . . . . . . . . . . . . . . . . . . . . . .
.
700/236;
700/115;
700/51
5 7 )
ABSTRACT
A y n a m i c l e a n r e p l e n i s h m e n t m e t h o d o r h a n d l i n g i n v e n t o r y
m a n a g e m e n t i s p r o v i d e d . T h e
m e t h o d
i n c l u d e s
p e r f o r m i n g
a n a l y s i s t o
d e t e r m i n e
a p r o j e c t e d i n v e n t o r y s t o c k . T h e
a n a l y
s i s
i s
performed n a c c o r d a n c e W i t h a t l e a s t one
of
s y n c h r o
nous mode
and a n a s y n c h r o n o u s mode. I n t h e
s y n c h r o n o u s
m o d e , a c o m p u t e r i s c o n ? g u r e d t o
p e r f o r m
t h e a n a l y s i s t o
d e t e r m i n e
t h e p r o j e c t e d i n v e n t o r y s t o c k
a f t e r c o n s u m p t i o n
h a s o c c u r r e d . The c o n s u m p t i o n i s
deemed
o
h a v e
o c c u r r e d
When ? r s t b i n o f a p l u r a l i t y o f
i n s
i s
consumed and h a n g e s
from a b i n state of on-hand t o t h e b i n state of m p t y .
I n
t h e
a s y n c h r o n o u s m o d e , t h e c o m p u t e r i s c o n ? g u r e d t o
p e r f o r m
t h e a n a l y s i s to d e t e r m i n e t h e p r o j e c t e d i n v e n t o r y s t o c k
a f t e r
a
p r e s e t t i m e
i n t e r v a l .
The
method
l s o
i n c l u d e s
c o m p a r i n g
t h e
p r o j e c t e d i n v e n t o r y s t o c k t o a
s a f e t y
s t o c k t o d e t e r m i n e
r e p l e n i s h m e n t .
CONSUMER
302
l
SUPPLIER
312
V
MATERIALS 3 1 8
SIGNAL 324
SUPPLIER
SIGNAL 326 314
3 5 0
V
MATERIALS
3 2 0
V
M A T E R I A L S 3 2 2
SIGNAL
328
I
I
I N T E L L I G E N C E |
I
|
|
I W L I I T i i O i
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8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
1 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
@D
—
I N
STATE
S
ON-HAND
\/\
1 0 2
B I N I S CONSUMED
AND
B I N STATE S
CHANGED
TO
EMPTY 1 0 4
I
A
SIGNAL
S
SENT TO A
S U P P L I E R .
B I N STATE S SET TO
ON-ORDER
m
1 0 6
S U P P L I E R
R E C E I V E S THE R E Q U E S T .
\/\
IS U P P L I E R
HA NDLES THE REQUEST \/\
1 1 0
v
SUPPLIER
SENDS MATERIALS TO
CONSUMER 1 1 2
CONSUMER RECEIVES THE
MATERIALS AND B I N
I S
F I L L E D ,
LA
B I N STATE S SET
TO
ON-HAND 1 1 4
F I G . 1
P R I O R A R T )
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
2 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
—>
N-HAND
\/\
2 0 0
I.
EMPTY \/\
2 0 2
ON-ORDER \/\
2 0 4
I
F I G . 2
P R I O R
A R T )
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8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
3 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
SUPPLIER
CONSUMER
312
302 i
l-— —I MATERIALS 1 s
I
SIGNAL 24
l
- S U P P L I E R
| _
S I G N A L 3 2 6
i
3 1 4
| | M A T E R I A L S 3 2 0
I N T E L L I G E N C E | —>
350
i | M A T E R I A L S
3 2 2
w
8 |
SIGNAL
2 8
z
I I
|
|_
_
_
F I G .
3
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8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
4 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
4 0 2
[\J
B I N
STATE
S
ON-HAND
I
B I N I S CONSUMED AND B I N STATE
S
4 0 4
CHANGED TO EMPTY \J
I 4 0 6
ANALYSIS AND
CALCULATE
N
PROJECTED
STOCK
l 4 0 8 4 1 0 4 1 2
\J V
\J
r\/
REPLENISH THE
REPLENISH THE CURRENT EMPTY
NO ACTION CURRENT
EMPTY
B I N AND ONE OR
B I N
MORE
OTHER
EMPTY
I N S
l 4
A S I G N A L I S SENT TO S U P P L I E R
B I N STATE S
MOVED TO
ON-ORDER
I
f\/ S U P P L I E R R E C E I V E S THE R E Q U E S T .
I
f\./ S U P P L I E R
HA NDLES THE REQUEST
8
1
S U P P L I E R SENDS
MATERIALS
TO
ONSUMER
4 2 0 l
CONSUMER RECE|vES THE
f\/
M A T E R I A L S
AND I N
I S
F I L L E D ,
2 B I N STATE S SET TO ON-HAND
F I G - 4
i
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
5 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
5 5 0
V‘
O N - H A N D > 4
T H I S
B I N I S CONSUMED
5 5 2
5 5 4
EMPTY
A N A L Y Z E
A N D
D E T E R M I N E
l r \ § 5 6
THE
NUMBER
OF B I N S TO
R E P L E N I S H
OF
B I N S
EEDED
>
0 ?
NO
5 6 0
NO ACTION O R DE R ONE B I N
\/
EDUCE
THE
NUMBER
OF B I N S
NEEDED
BY
5 6 3 / ?
R E C E I V E D M A T E R I A L S
FROM
S U P P L I E R
F I G . 5
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
6 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
[\J
D E N T I F Y
CURRENT
INVENTORY ON-HAND
6 0 2 l
SUBTRA CT PROJECTED CONSUMPTION
6 0 ? ‘ F R O M
C U R R E N T I N V E N T O R Y
O N - H A N D
I
A D D INVENTORIES TO BE RECEIVED
6 0 / 6 \ ’
D U R I N G
L E A D T I M E
+ F I G .
6
DETERMINE PROJECTED INVENTORY
r\/ STOCK
ON-HAND
6 0 8
l
COMPARE
PROJECTED INvENTORY STOCK
6 1 0 TO SAFETY STOCK
6 1 8
6 ” ‘
S
NO RELEASE A
1
C T I O N Y E S R E P L E N I S H M E N T
NEEDED SIGNAL FOR THE
EMPTY
I N
M A RK
I - I E
B I N
AS
[\J
ON-ORDER
6 2 0
l
INCREASE THE
PROJECTED
6 2 f ? ’ I N v E N T O R Y
S T O C K
BY ONE B I N
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P a t e n t A p p l i c a t i o n P u b l i c a t i o n S e p .
4 , 2 0 0 8 S h e e t
7 0 f 7
US
2 0 0 8 / 0 2 1 5 1 8 0 A 1
CALCULATE
PROJECTED
\J CONSUMPTION DURING LEAD T I M E
7 0 2 +
\
ADD
SAFETY
STOCK
I
ROUND UP TO
INTEGRAL
M U L T I P L E OF
OT I Z E . T H I S VALUE
S
THE NEW
7 0 8 REORDER
P O I N T
EW REORDE
P O I N T
I S
SAME AS CURRENT
EORDER
O I N
YES
7 1 0
7 1 / 2 \ _ , S E T A S
C U R R E N T R E O R D E R
P O I N T
F I G . 7
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8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
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US 008/0215180
A 1
ARRANGEMENTFORDYNAMIC LEAN
REPLENISHMENT
AND
METHODS
THEREFOR
BACKGROUND
OF
THE
INVENTION
[ 0 0 0 1 ] I n
t o d a y ’ s
b u s i n e s s
W o r l d ,
i n v e n t o r y
m a n a g e m e n t
p l a y s a n
i m p o r t a n t
r o l e i n
a
c o m p a n y ’ s
e f ? c i e n c y
a n d
p r o ? t
a b i l i t y .
I n a
c o m p a n y ,
t h e h i g h i n v e n t o r y l e v e l s e . g . , r a W
m a t e r i a l , W o r k - i n p r o g r e s s m a t e r i a l s , e t c . ) c a n s i g n i ? c a n t l y
i n c r e a s e
c a r r y i n g
c o s t s
a n d
a r t s h a n d l i n g c o s t s .
I n i n v e n t o r y
management, a
company
r i e s t o
m a i n t a i n t h e l o W e s t
l e v e l of
i n v e n t o r y
W h i l e
p r e v e n t i n g i n v e n t o r y
s t o c k - o u t s .
As
d i s
c u s s e d h e r e i n ,
a
s t o c k - o u t r e f e r s t o
t h e s i t u a t i o n
i n Which
i n s u f ? c i e n t i n v e n t o r i e s a r e a v a i l a b l e r e su l t i n g i n
d e l a y e d p r o
d u c t i o n
of
one r m o r e
customer
r d e r s . T h u s , t h e a b i l i t y f o r
a
company t o d e t e r m i n e
When
m a t e r i a l r e p l e n i s h m e n t
m a y
need
o
occur s
e s s e n t i a l i n
m a i n t a i n i n g a loW e v e l of n v e n
t o r y
W h i l e
p r e v e n t i n g
s t o c k - o u t s .
[ 0 0 0 2 ] An n v e n t o r y s y s t e m t h a t h a s b e e n i m p l e m e n t ed b y
c o m p a n i e s
t o
a d d r e s s
m a t e r i a l
r e p l e n i s h m e n t
i s
t h e
Kanban
s y s t e m . I n t h e Kanban s y s t e m , a p u l l
b a s e d s y s t e m i s
i m p l e
mented
n
Which
s u p p l i e r r e p l e n i s h e s
m a t e r i a l
When con
sumer s e n d s a r e p l e n i s h m e n t
s i g n a l . T y p i c a l l y ,
m a t e r i a l s a r e
s t o r e d i n b i n s o r s t a n d a r d l o t s i Z e s i n a Kanban s y s t e m .
A s
a
b i n
i s c o n s u m e d , a s i g n a l i s
s e n t
t o t h e s u p p l i e r t o r e p l e n i s h
t h e b i n . Upon r e c e i v i n g t h e s i g n a l , t h e
s u p p l i e r
s e n d s t h e
m a t e r i a l s t o t h e consumer.
[ 0 0 0 3 ] To
a c i l i t a t e d i s c u s s i o n ,
F I G . 1
s h o W s
a s i m p l e ?oW
c h a r t d i a g r a m
i l l u s t r a t i n g
t h e
m e t h o d f o r i m p l e m e n t i n g
a
Kanban
s y s t e m .
[ 0 0 0 4 ] At ? r s t s t e p 1 0 2 , a b i n may ave state
of
n - h a n d .
I n
a n e x a m p l e , t h e b i n s f u l l o f a t e r i a l s and no consumption
h a s
o c c u r r e d .
[ 0 0 0 5 ] At a
n e x t
s t e p 1 0 4 , t h e
b i n h a s been consumed and
t h e
b i n
s t a t e
h a s
c h a n g e d
o
e m p t y .
G e n e r a l l y ,
c o n s u m p t i o n
s
de?ned s
e i t h e r a
neWly opened box r an
emptied o x . I n an
o p e n e d b o x s i t u a t i o n ,
t h e b i n
may a v e b e e n o p e n e d ;
hoW
e v e r ,
no
a c t u a l consumption may ave o c c u r r e d . I n an emp
t i e d
box i t u a t i o n ,
t h e m a t e r i a l s t o r e d i n t h e b i n h a s b e e n u l l y
c o n s u m e d . R e g a r d l e s s a s hoW c o n s u m p t i o n i s de?ned by a
company,
a consumed
b i n
changes t h e state of t h e
b i n
t o
e m p t y .
[ 0 0 0 6 ] At a
n e x t
s t e p
1 0 6 , a s i g n a l h a s been s e n t
t o
t h e
s u p p l i e r . I n a n e x a m p l e , When
h e
b i n
s t a t e
i s e m p t y ,
a
s i g n a l
e . g . , e l e c t r o n i c s i g n a l ) may
e
s e n t t o t h e s u p p l i e r t o r e p l e n
i s h t h e
consumed
i n . I n t h e
t r a d i t i o n a l Kanban
s y s t e m , t h e
amount f e p l e n i s h m e n t
s
u s u a l l y e q u a l to t h e amount f h e
immediate consumption. I n an
e x a m p l e ,
When a b i n i s
con
sumed, a s i g n a l
may
be s e n t t o r e p l e n i s h one
b i n .
Once t h e
s i g n a l h a s
b e e n
s e n t , t h e b i n s t a t e may h a n g e to
o n - o r d e r .
[ 0 0 0 7 ] At a n e x t s t e p 1 0 8 , t h e s u p p l i e r r e c e i v e s t h e r e q u e s t
from
t h e
c o n s u m e r .
S i n c e a
Kanban system may be
a p p l i e d
i n t e r n a l l y
a s W e l l a s e x t e r n a l l y , a s u p p l i e r may e i t h e r
be an
o u t s i d e vendor or an n t e r n a l vendor.
I n
an example, an out
s i d e vendor may e
a s u p p l i e r t h a t p r o v i d e s
one o r m o r e
p a r t s / se r v i c e s f o r
t h e consum er and
s n o t
p a r t of h e co m
p a n y .
I n a n o t h e r
example,
an i n t e r n a l vendor may be a s u p
p l i e r
t h a t i s
p a r t o f
h e company
n d s
l o c a t e d u p s t r e a m
f r o m
t h e consumer,
and
s
r e s p o n s i b l e f o r
p r o v i d i n g
one
o r
m o r e
p a r t s /
s e r v i c e d o W n s t r e a m .
[ 0 0 0 8 ] At a n e x t s t e p 1 1 0 , t h e
s u p p l i e r
may h a n d l e t h e
r e q u e s t
from
t h e c o n s u m e r .
The s u p p l i e r
may
i t h e r p r o c u r e
t h e i n v e n t o r i e s ,
m a n u f a c t u r e
t h e i n v e n t o r i e s , o r
p r o v i d e
a
s e r v i c e
e . g . ,
p a i n t a c a r ) . T h e h a n d l i n g o f t h e r e q u e s t may e
S e p . 4 , 2 0 0 8
d e p e n d e n t upon p r e - a r r a n g e d
t e r m s .
The
consumer
and
t h e
s u p p l i e r m ay a v e
e s t a b l i s h e d p o l i c i e s
on hoW
r e q u e s t
may
be h a n d l e d . I n an example, i f a
r e q u e s t
i s
s e n t
b e f o r e
n o o n ,
t h e n
t h e s u p p l i e r
may a n d l e
t h e
r e q u e s t
W i t h i n t h e
d a y .
I n
a n o t h e r e x a m p l e ,
i f
a r e q u e s t
i s
r e c e i v e d
on
r i d a y ,
t h e s u p
p l i e r may
o t
h a n d l e t h e
r e q u e s t u n t i l
t h e n e x t
b u s i n e s s
d a y
e . g . ,
M o n d a y ) .
[ 0 0 0 9 ] At
s t e p
1 1 2 , t h e s u p p l i e r s e n d s t h e c o n s u m e r t h e
r e q u e s t e d m a t e r i a l s .
I n
a n e x a m p l e , f o r
a n
o u t s i d e s u p p l i e r ,
t h e
s u p p l i e r
may s h i p t h e m a t er i a l s to t h e c o n s u m e r .
[ 0 0 1 0 ] At t e p 1 1 4 ,
t h e consumer
may
e c e i v e t h e m a t e r i a l s
and h e
b i n may
e ? l l e d .
Once
h e
b i n h a s
been
l l e d ,
t h e
b i n
s t a t e m ay e changed from n - o r d e r back
o
o n - h a n d .
[ 0 0 1 1 ] The method d e s c r i b e d i n s t e p s 102 to 114
i s a n
i t e r a t i v e
method
h a t m a y be performed s b i n s
a r e consumed
a n d
r e p l e n i s h e d .
[ 0 0 1 2 ] F I G . 2 i s
a
s i m p l e d i a g r a m i l l u s t r a t i n g
t h e
d i f f e r e n t
b i n s t a t e s i n a t r a d i t i o n a l Kanban
s y s t e m .
[ 0 0 1 3 ] At state
2 0 0 ,
a b i n state i s o n - h a n d .
I n
an
example,
t h e
b i n
i s
? l l e d
W i t h
m a t e r i a l s
and no
consumption
h a s
o c c u r r e d .
[ 0 0 1 4 ] At a s t a t e
2 0 2 ,
t h e b i n s t a t e i s e m p t y .
A s
aforemen
t i o n e d , an empty s t a t e
may
ccur When
h e b i n
i s e i t h e r i n
an
o p e n e d box ( o p e n e d b u t n o t c o n s u m e d ) o r
a n
e m p t i e d
( o p e n e d a n d
h a s
b e e n
c o n s u m e d ) b o x s i t u a t i o n .
[ 0 0 1 5 ] At
state
2 0 4 ,
t h e b i n
state
i s o n - o r d e r . An
n - o r d e r
s t a t e may occur When
h e bin
has
been consumed
and
a
r e p l e n i s h m e n t
s i g n a l
h a s
b e e n s e n t
t o a s u p p l i e r .
[ 0 0 1 6 ]
The
t r a n s i t i o n from s t a t e s 202 t o
204
m ay o c c u r
W i t h o u t
d e l a y . I n an
x a m p l e ,
once
b i n
state
h a s
changed o
e m p t y ,
a
r e p l e n i s h m e n t
s i g n a l
may
be s e n t i m m e d i a t e l y to
a
s u p p l i e r a n d t h e
b i n
s t a t e i s
i m m e d i a t e l y
b e c h a n g e d t o on
o r d e r .
[ 0 0 1 7 ] S i n c e t h e
r e p l e n i s h m e n t
l o o p d e s c r i b e d
a b o v e
h a s a
o n e - t o - o n e r e p l a c e m e n t
r a t i o ,
a
company
m ay
be u n a b l e
t o
h a n d l e
a n u n e x p e c t e d
s p i k e i n demand
n d /
r may a v e h i g h
i n v e n t o r y c a r r y i n g c o s t s When demand
u n e x p e c t e d l y
d e c l i n e s .
To a d d r e s s
? u c t u a t i o n s , a company m ay m a i n t a i n
s a f e t y
s t o c k
i n
a n
a t t e m p t
t o a b s o r b t h e c h a n g i n g demands
a n d s e t t i n g t h e c o r r e c t
s a f e t y
s t o c k
i s
v e r y i m p o r t a n t .
[ 0 0 1 8 ]
The
r a d i t i o n a l
Kanban y s t e m
s an x c e l l e n t
i n v e n
t o r y management
system f a c t u a l demand
a t e s
a r e c o n s t a n t
and h a t
demand
a t e i s
t h e
s a me a t e t h a t
has
been
t i l i Z e d
t o
c a l c u l a t e
t h e r e p l e n i s h m e n t
l o o p
s i Z e . R e a l i s t i c a l l y , t h e a b i l
i t y t o p r o j e c t
an a c c u r a t e
demand a t e may
e i f ? c u l t .
I n an
e x a m p l e , i f d e m a n d s c h a n g e s a n d
s t a b i l i Z e s
a n d t h e s a f e t y
s t o c k
h a s n o t been a d j u s t e d , a t r a d i t i o n a l Kanban s y s t e m
e . g . , r e p l e n i s h m e n t l o o p W i t h h e s a f e t y s t o c k )
may
e i n s u f
? c i e n t to a d d r e s s
t h e
? u c t u a t i n g d e m a n d s .
I n
an e x a m p l e ,
demand
may
a v e i n c r e a s e d a n d s t a b i l i Z e d r e s u l t i n g i n s a f e t y
s t o c k
b e i n g
u t i l i Z e d
t o
a d d r e s s t h e i n c r e a s e
i n
demand.
Over
t i m e , t h e i n v e n t o r y l e v e l may d r o p a n d s a f e t y s t o c k may e
i n s u f ? c i e n t
t o p r o t e c t a g a i n s t u n e x p e c t e d
s p i k e s
r e s u l t i n g i n
s t o c k - o u t .
I n
a n o t h e r e x a m p l e , demand
may a v e d e c r e a s e d
a n d
s t a b i l i Z e d
r e s u l t i n g i n
f e W e r
i n v e n t o r i e s b e i n g u t i l i Z e d .
Over
t i m e , t h e i n v e n t o r y l e v e l may
become e l e v a t e d
a n d
e x c e s s i n v e n t o r i e s
may
e c a r r i e d r e s u l t i n g i n h i g h i n v e n t o r y
c o s t o n - h a n d . A s can be
s e e n , t h e
t r a d i t i o n a l Kanban system
may e s e n s i t i v e t o
demand h a n g e s
b u t may
o t
b e e q u i p p e d
t o
a d d r e s s
t h e demand
h a n g e s
W i t h o u t human n t e r v e n t i o n .
[ 0 0 1 9 ] I n
d d i t i o n , t h e Kanban y s t e m may l s o r e q u i r e h a t
t h e r e p l e n i s h m e n t t i m e e . g . ,
t i m e
a s u p p l i e r may t a k e
t o
p r o v i d e
t h e m a t e r i a l s t o
r e p l e n i s h
a b i n )
i s
t h e
same
s t h e one
t h a t h a s b e e n
u t i l i Z e d
o
c a l c u l a t e
t h e r e p l e n i s h m e n t l o o p
s i Z e .
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H o w e v e r , s u p p l i e r s may
o t a l w a y s
b e a b l e to a d h e r e t o t h e
r e p l e n i s h m e n t
s c h e d u l e
as
a g r e e d upon
by h e consumer and
t h e s u p p l i e r s . I n s u c h a s i t u a t i o n , t h e
s a f e t y
s t o c k may
b e
e m p l o y e d t o a d d r e s s t h e
s h o r t a g e .
H o w e v e r , i f t h e
s u p p l i e r s
c o n t i n u e
t o
m i s s
d e a d l i n e s , s a f e t y s t o c k s
may
b e
q u i c k l y
d e p l e t e d .
S i n c e a
t r a d i t i o n a l Kanban
system
assumes
a r e l i
a b l e r e p l e n i s h m e n t t i m e , s t o c k - o u t s may
c c u r .
[ 0 0 2 0 ]
T o a d d r e s s t h e c h a n g e s i n demand a n d
r e p l e n i s h
m e n t , t h e Kanban r e p l e n i s h m e n t l o o p s i Z e
may h a v e
t o b e
r e s i Z e d . As d i s c u s s i n g h e r e i n , l o o p
s i Z e
r e f e r s t o
t h e number
o f i n s . R e s i z i n g
may
e a c o m p l e x
p r o c e s s t h a t may
e q u i r e
t r a i n e d
human
r e s o u r c e s .
I n an
example,
t r a i n e d human
r e s o u r c e s m ay have t o
monitor
and a n a l y Z e t h e demands i n
o r d e r
t o
d e t e r m i n e
t h e r e c e n t demand
p a t t e r n s .
F u r t h e r ,
t r a i n e d r e s o u r c e s m ay have t o monitor
t h e
r e p l e n i s h m e n t
c y c l e t o
d e t e r m i n e t h e
r e p l e n i s h m e n t
t r e n d .
The
p r o c e s s o f
m o n i t o r i n g
may
e
t e d i o u s a n d may
e
s u s c e p t i b l e to
human
e r r o r s ,
e s p e c i a l l y i f
t h e number f i n s i s l a r g e .
C o n s i d e r
t h e
s i t u a t i o n W h e r e i n , f o r e x a m p l e , a t y p i c a l m a n u f a c t u r i n g l a n t
may h a v e 2 , 0 0 0
to 5 , 0 0 0 d i f f e r e n t
p a r t s
t h a t a r e needed i n
o r d e r o p r o d u c e
a
p r o d u c t . Each a r t may e a s s o c i a t e d W i t h
one
r m o re i n s . A s a r e s u l t , t h e nu mb e r of i n s t h a t have o
be
m o n i t o r e d m ay become a
l a r g e
a d m i n i s t r a ti v e t a s k t h a t
r e q u i r e s s e v e r a l s k i l l e d
W o r k e r s .
[ 0 0 2 1 ]
Once t h e t ed i o u s a n d c o m p l e x p r o c e s s o f m o n i t o r
i n g
h a s
o c c u r r e d , t h e
c h a n g e s
i n
t h e
number
f
b i n s may e
d e t e r m i n e d . I n t h e s i t u a t i o n d e s c r i b e d a b o v e , t h e s t o r a g e o f
t h e
v a s t
number f a r t s
may
e q u i r e a complex t o r a g e i n f r a
s t r u c t u r e to be s t a b l i s h e d . A s r e s u l t , changes o t h e number
o f b i n s may r e q u i r e c h a n g e s t o t h e c o m p l e x s t o r a g e i n f r a
s t r u c t u r e
t h a t r e q u i r e s
t i m e
a n d s p a c e .
I n a d d i t i o n ,
t h e
c h a n g e s may a v e
o b e g r a d u a l l y i n t e g r a t e d
n t o
a c o m p a n y ’ s
c u r r e n t
Kanban
system s i n c e most companies
a r e unable
t o
a c c o m m o d a t e
t h e c h a n g e s q u i c k l y . T h u s , i n v e n t o r y
m a n a g e
ment
i n t h e
Kanban
system can
be
a
l a r g e endeavor
t h a t
becomes
c o s t l y
t o
m a i n t a i n
i f
demand
h a n g e s
r e s u l t
i n
con
s t a n t
r e s i Z i n g .
SUMMARYOF
INVENTION
[ 0 0 2 2 ]
The
i n v e n t i o n r e l a t e s , i n a n embodiment, to a
d y n a m i c l e a n
r e p l e n i s h m e n t
m e t h o d
f o r h a n d l i n g
i n v e n t o r y
m a n a g e m e n t . The
m e t h o d i n c l u d e s
p e r f o r m i n g a n a l y s i s t o
d e t e r m i n e
a p r o j e c t e d i n v e n t o r y
s t o c k .
The a n a l y s i s
i s
p e r
formed n accordance With
t l e a s t
one of synchronous
m o d e
and an asynchronous
mode. n t h e
s y n c h r o n o u s
mode, a com
p u t e r i s
c o n ? g u r e d t o
p e r f o r m t h e
a n a l y s i s t o
d e t e r m i n e t h e
p r o j e c t e d i n v e n t o r y s t o c k a f t e r
c o n s u m p t i o n
h a s
o c c u r r e d .
The
consumption s deemed o have c c u r r e d When ? r s t b i n
o f
p l u r a l i t y
o f i n s
i s consumed
and h a n g e s
from b i n
state
o f o n - h a n d t o t h e
b i n
s t a t e o f
e m p t y .
I n t h e a s y n c h r o n o u s
m o d e , t h e c o m p u t e r
i s
c o n ? g u r e d
t o
p e r f o r m
t h e a n a l y s i s
t o
d e t e r m i n e
t h e
p r o j e c t ed i n v e n t o r y
s t o c k a f t e r a p r e s e t
t i m e
i n t e r v a l . The
method
a l s o i n c l u d e s c o m p a r i n g t h e p r o j e c t e d
i n v e n t o r y s t o c k
t o a s a f e t y
s t o c k
to
d e t e r m i n e r e p l e n i s h m e n t .
[ 0 0 2 3 ] I n
a n o t h e r embodiment, t h e
i n v e n t i o n
r e l a t e s t o a
d y n a m i c l e a n
r e p l e n i s h m e n t a r r a n g e m e n t o r h a n d l i n g i n v e n
t o r y m a n a g e m e n t . The a r r a n g e m e n t i n c l u d e s a p l u r a l i t y o f
b i n s , e a c h b i n o f t h e p l u r a l i t y o f
i n s b e i n g a s s o c i a t e d
W i t h a
b i n s t a t e . The i n
t a t e i n c l u d e s
o n - h a n d , e m p ty , and n - o r d e r .
The r r a n g e m e n t
a l s o
i n c l u d e s a computer
o r
p e r f o r m i n g an
a n a l y s i s t o
d e t e r m i n e a
p r o j e c t e d i n v e n t o r y s t o c k . T h e
a n a l y
s i s i s performed n a c c o r d a n c e W i t h a t l e a s t one
of
s y n c h r o
nous
mode and an a s y n c h r o n o u s
mode. I n t h e
s y n c h r o n o u s
m o d e ,
t h e c o m p u t e r i s
c o n ? g u r e d t o p e r f o r m t h e a n a l y s i s
t o
S e p . 4 , 2 0 0 8
d e t e r m i n e t h e p r o j e c t e d i n v e n t o r y
s t o c k
a f t e r c o n s u m p t i o n
h a s
o c c u r r e d .
The
c o n s u m p t i o n
i s deemed
o h a v e
o c c u r r e d
When a ? r s t b i n o f t h e p l u r a l i t y o f b i n s
i s consumed and
changed
from t h e b i n s t a t e o f on-hand
t o
t h e b i n s t a t e o f
e m p t y .
I n t h e
a s y n c h r o n o u s
m o d e ,
t h e
c o m p u t e r s c o n ? g u r e d
t o
p e r f o r m t h e
a n a l y s i s t o d e t e r m i n e
t h e
p r o j e c t ed i n v e n t o r y
s t o c k
a f t e r
a
p r e s e t t i m e i n t e r v a l .
[ 0 0 2 4 ] I n y e t
a n o t h e r e m b o d i m e n t , t h e
i n v e n t i o n
r e l a t e s
t o
an
a r t i c l e of manufacture
c o m p r i s i n g
a program
s t o r a g e
medium
h a v i n g
c o m p u t e r
r e a d a b l e
c o d e e m b o d i e d t h e r e i n .
The o m p u t e r r e a d a b l e c o d e s c o n ? g u r e d o h a n d l e i n v e n t o r y
m a n a g e m e n t .
The
r t i c l e o f
m a n u f a c t u r e
i n c l u d e s
c o m p u t e r
r e a d a b l e c o d e
f o r
p e r f o r m i n g a n a l y s i s to d e t e r m i n e
a
p r o
j e c t e d i n v e n t o r y s t o c k .
T h e a n a l y s i s i s p e r f o r m e d
i n a c c o r
dance
With at l e a s t one of
synchronous
mode nd an
asyn
c h r o n o u s mode. I n t h e s y n c h r o n o u s mode, a c o m p u t e r i s
c o n ? g u r e d o
p e r f o r m t h e
a n a l y s i s
t o
d e t e r m i n e
t h e
p r o j e c t e d
i n v e n t o r y s t o c k a f t e r c o n s u m p t i o n h a s o c c u r r e d . The
c o n
sumption s
deemed
t o
have
o c c u r r e d
When a ? r s t b i n of a
p l u r a l i t y o f
i n s
i s consumed and h a n g e s from b i n
s t a t e
o f
o n - h a n d to t h e b i n s t a t e o f e m p t y . I n t h e a s y n c h r o n o u s mode,
t h e
c o m p u t e r
i s
c o n ? g u r e d t o
p e r f o r m t h e
a n a l y s i s t o d e t e r
mine h e p r o j e c t e d i n v e n t o r y s t o c k
f t e r
a p r e s e t t i m e n t e r v a l .
The
r t i c l e
o f m a n u f a c t u r e
a l s o i n c l u d e s c o m p u t e r
r e a d a b l e
c o d e f o r
c o m p a r i n g t h e p r o j e c t e d i n v e n t o r y s t o c k t o a
s a f e t y
s t o c k to d e t e r m i n e r e p l e n i s h m e n t .
[ 0 0 2 5 ] I n y e t
a n o t h e r e m b o d i m e n t , t h e
i n v e n t i o n
r e l a t e s
t o
a
d y n a m i c
l e a n r e p l e n i s h m e n t m e t h o d
o r
h a n d l i n g i n v e n t o r y
m a n a g e m e n t . The m e t h o d i n c l u d e s p e r f o r m i n g a n a l y s i s t o
d e t e r m i n e
a
r e o r d e r
p o i n t .
The
a n a l y s i s
i s p e r f o r m e d
i n a n
a s y n c h r o n o u s
m o d e .
I n
t h e
a s y n c h r o n o u s
m o d e , t h e
com
p u t e r
i s
c o n ? g u r e d t o p e r f o r m t h e a n a l y s i s t o d e t e r m i n e t h e
r e o r d e r
p o i n t
a f t e r
a p r e s e t t i m e i n t e r v a l .
The method
a l s o
i n c l u d e s comparing t h e r e o r d e r p o i n t
t o a c u r r e n t
r e o r d e r
p o i n t t o d e t e r m i n e r e p l e n i s h m e n t .
[ 0 0 2 6 ] I n y e t
a n o t h e r
e m b o d i m e n t ,
t h e i n v e n t i o n
r e l a t e s
t o
a d y n a m i c l e a n r e p l e n i s h m e n t a r r a n g e m e n t f o r
h a n d l i n g
i n v e n t o r y
management
i n
a c o m p a n y . The
a r r a n g e m e n t
i n c l u d e s a p l u r a l i t y o f o t
s i Z e s .
Each o t s i Z e o f t h e p l u r a l i t y
of l o t s i Z e s
i n c l u d e s a
set of l o t s .
The
arrangement a l s o
i n c l u d e s a
computer
f o r
p e r f o r m i n g
a n a l y s i s
t o d e t e r m i n e
a
r e o r d e r p o i n t . T h e a n a l y s i s i s
p e r f o r m e d
i n a n a s y n c h r o n o u s
m o d e .
I n t h e a s y n c h r o n o u s
mode
h e c o m p u t e r i s c o n ? g u r e d
t o p e r f o r m t h e a n a l y s i s t o d e t e r m i n e t h e r e o r d e r p o i n t
a f t e r
a
p r e s e t t i m e i n t e r v a l .
[ 0 0 2 7 ]
The above summary e l a t e s t o o n l y one f t h e many
embodiments o f t h e i n v e n t i o n d i s c l o s e d
h e r e i n
and i s n o t
i n t e n d e d t o l i m i t t h e
s c o p e
o f t h e i n v e n t i o n ,
Which s s e t
f o r t h
i n t h e c l a i m s h e r e i n . T h e s e and o t h e r f e a t u r e s
o f
t h e p r e s e n t
i n v e n t i o n
W i l l be d e s c r i b e d i n
more
d e t a i l beloW i n t h e
d e t a i l e d d e s c r i p t i o n
o f
t h e i n v e n t i o n
a n d
i n
c o n j u n c t i o n W i t h
t h e f o l l o W i n g ? g u r e s .
B R I E F DESCRIPTIONOFTHEDRAWINGS
[ 0 0 2 8 ]
The
p r e s en t i n v e n t i o n i s
i l l u s t r a t e d b y
Way o f
e x a m p l e ,
a n d n o t
b y
Way o f l i m i t a t i o n , i n t h e
? g u r e s
o f t h e
accompanying d r a W i n g s and n Which
i k e r e f e r e n c e
numer
a l s r e f e r t o
s i m i l a r
e l e m e n t s and n W h i c h :
[ 0 0 2 9 ] F I G . 1 s h o W s a s i m p l e ?oW h a r t d i a g r a m
i l l u s t r a t
i n g
t h e
m e t h o d f o r
i m p l e m e n t i n g t h e
Kanban s y s t e m .
[ 0 0 3 0 ] F I G .
2
i s a s i m p l e d i a g r a m i l l u s t r a t i n g t h e d i f f e r e n t
b i n
s t a t e s
i n a t r a d i t i o n a l
Kanban
s y s t e m .
[ 0 0 3 1 ]
F I G .
3 s h o W s , i n a n embodiment f t h e i n v e n t i o n , a
b l o c k
d i a g r a m
o f
a d y n a m i c l e a n
r e p l e n i s h m e n t
a r r a n g e m e n t .
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[ 0 0 3 2 ]
F I G .
4 s h o w s , i n
an
embodiment f t h e i n v e n t i o n , a
s i m p l e
?oW h a r t i l l u s t r a t i n g
a
d y n a m i c l e a n
r e p l e n i s h m e n t
m e t h o d .
[ 0 0 3 3 ] F I G . 5 s h o w s ,
i n
a n embodiment
o f t h e i n v e n t i o n ,
s i m p l e
d i a g r a m
i l l u s t r a t i n g
t h e d i f f e r e n t
b i n
s t a t e s
i n a
d y n a m i c
l e a n
r e p l e n i s h m e n t a r r a n g e m e n t .
[ 0 0 3 4 ]
F I G .
6
s h o W s ,
i n
an
embodiment f t h e i n v e n t i o n , a
s i m p l e
?oW c h a r t
i l l u s t r a t i n g t h e
m e t h o d s
f o r
p e r f o r m i n g
a n a l y s i s
a n d
c a l c u l a t i n g t h e p r o j e c t e d
i n v e n t o r y
s t o c k .
[ 0 0 3 5 ]
F I G .
7
s h o W s ,
i n a n embodiment f h e i n v e n t i o n ,
an
e x a m p l e o f a How c h a r t i l l u s t r a t i n g
hoW
t h e
d y n a m i c l e a n
r e p l e n i s h m e n t method
may e
a p p l i e d
i n a n
MRP y s t e m .
DETAILEDDESCRIPTIONOFEMBODIMENTS
[ 0 0 3 6 ]
The
p r e s e n t i n v e n t i o n W i l l noW be d e s c r i b e d i n
d e t a i l With r e f e r e n c e t o
a
feW
embodiments
t h e r e o f
a s
i l l u s
t r a t e d i n
t h e
a c c o m p a n y i n g
d r a W i n g s . I n t h e f o l l o W i n g
d e s c r i p t i o n , numerous s p e c i ? c
d e t a i l s
a r e set
f o r t h
i n
o r d e r
t o
p r o v i d e a
t h o r o u g h
u n d e r s t an d i n g o f t h e p r e s e n t i n v e n t i o n .
I t
W i l l
b e
a p p a r e n t ,
h o W e v e r ,
to
one
s k i l l e d i n
t h e
a r t ,
t h a t
t h e
p r e s en t i n v e n t i o n m ay be p r a c t i c e d
W i t h o u t s ome o r
a l l of
t h e s e s p e c i ? c d e t a i l s . I n
o t h e r
i n s t a n c e s , W e l l knoWn r o c e s s
s t e p s a n d / o r s t r u c t u r e s
h a v e
n o t
been
d e s c r i b e d i n
d e t a i l i n
o r d e r
to
n o t u n n e c e s s ar i l y o b s c u r e
t h e
p r e s e n t i n v e n t i o n .
[ 0 0 3 7 ] V a r i o u s
embodiments
a r e d e s c r i b e d h e r e i n b e l o W ,
i n c l u d i n g
m e t h o d s
a n d t e c h n i q u e s . I t
s h o u l d
b e k e p t i n
mind
t h a t t h e i n v e n t i o n
might
a l s o
c o v e r
a r t i c l e s o f m a n u f a c t u r e
t h a t i n c l u d e s a
computer readable
medium on Which com
p u t e r - r e a d a b l e
i n s t r u c t i o n s f o r
c a r r y i n g o u t
e m b o d i m e n t s o f
t h e i n v e n t i v e
t e c h n i q u e a r e s t o r e d .
The computer
r e a d a b l e
medium
ay n c l u d e ,
f o r
e x a m p l e ,
s e m i c o n d u c t o r , m a g n e t i c ,
o p t o - m a g n e t i c , o p t i c a l , o r o t h e r f o r m s o f c o m p u t e r r e a d a b l e
medium
f o r s t o r i n g c o m p u t e r
r e a d a b l e
c o d e . F u r t h e r , t h e
i n v e n t i o n may l s o
c o v e r
a p p a r a t u s e s f o r p r a c t i c i n g embodi
m e n t s o f
t h e
i n v e n t i o n .
Such
p p a r a t u s
may
n c l u d e
c i r c u i t s ,
d e d i c a t e d a n d / o r p r o g r a m m a b l e , t o
c a r r y
o u t
t a s k s p e r t ai n i n g
t o embodiments f h e
i n v e n t i o n .
Examples f
s u c h
a p p a r a t u s
i n c l u d e a
g e n e r a l - p u r p o s e
computer a n d / o r a
d e d i c a t e d com
p u t i n g d e v i c e When a p p r o p r i a t e l y p r o g r a m m e d a n d may
i n c l u d e
a combination
of
computer/computing d e v i c e and
d e d i c a t e d / p r o g r a m m a b l e c i r c u i t s a d a p t e d f o r
t h e
v a r i o u s
t a s k s
p e r t a i n i n g t o embodiments
o f t h e i n v e n t i o n .
[ 0 0 3 8 ] I n
a c c o r d a n c e W i t h embodiments o f
t h e p r e s e n t
i n v e n t i o n ,
t h e r e i s p r o v i d e d a d y n a m i c l e a n r e p l e n i s h m e n t
a r r a n g e m e n t a n d /
r
method
o r s u s t a i n i n g
a n o p t i m a l i n v e n
t o r y l e v e l W h i l e m a i n t a i n i n g a s u ? i c i e n t s a f e t y s t o c k .
Embodiment o f t h e
i n v e n t i o n f u r t h e r p r o v i d e s
a s t a t i s t i c a l
method
o r
a n a l y Z i n g
t h e
h i s t o r i c a l
d a t a i n o r d e r o d e t e r m i n e
t h e
p r o j e c t e d
i n v e n t o r y
s t o c k
i n o r d e r t o d e t e r m i n e t h e
amount
o f
i n v e n t o r y
t h a t may need
t o b e
r e p l e n i s h e d .
A s
d i s c u s s e d
h e r e i n ,
p r o j e c t ed i n v e n t o r y
s t o c k
r e f e r s t o
t h e
amount f
n v e n t o r y
t h a t may e e d t o b e
r e p l e n i s h e d
i n
o r d e r
t o m a i n t a i n t h e
s a f e t y
s t o c k .
[ 0 0 3 9 ] I n o n e a s p e c t o f
t h e
i n v e n t i o n ,
t h e
i n v e n t o r h e r e i n
r e a l i Z e d t h a t t h e p r i o r
a r t Kanban
s y s t e m p r o v i d e s f o r a
one
t o - o n e r e p l e n i s h m e n t . I n t h e p r i o r a r t ,
r e p l e n i s h m e n t
o c c u r s
a s consumption
c c u r s .
A s r e s u l t , replenishmentmay
ccur
r e g a r d l e s s o f t h e r a t e o f
c o n s u m p t i o n
r e s u l t i n g i n i n a c c u r a t e
i n v e n t o r y
l e v e l When
demand
a t t e r n
c h a n g e s .
[ 0 0 4 0 ]
I n o n e
a s p e c t
o f
t h e
i n v e n t i o n ,
t h e i n v e n t o r
h e r e i n
r e a l i Z e d t h a t
r e p l e n i s h m e n t
may
o t
have t o
occur immedi
a t e l y
a f t e r c o n s u m p t i o n h a s o c c u r r e d .
I n s t e a d ,
h i s t o r i c a l d a t a
may b e e m p l o y e d t o p r o j e c t
u p c o m i n g i n v e n t o r y
n e e d s
t h e r e b y e n ab l i n g r e p l e n i s h m e n t o o c c u r
d y n a m i c a l l y .
H e n c e ,
S e p . 4 , 2 0 0 8
b y d y n a m i c a l l y a d j u s t i n g t h e
r e p l e n i s h m e n t
a m o u n t , t h e
i n v e n t o r s
h e r e i n
r e a l i Z e d
t h a t
d a i l y
? u c t u a t i o n s may
b e
a c c o m m o d a t e d W i t h o u t
b e i n g
e n c u m b e r e d b y t h e c o m p l e x
a n d
e x p e n s i v e
r e s i Z i n g
m e t h o d ,
W h i c h
may e a c o m p l e x
a n d
e x p e n s i v e
m e t h o d
t h a t
may
e q u i r e
t i m e
t o
b e i m p l e m e n t e d .
[ 0 0 4 1 ] I n t h i s d o c u m e n t , v a r i o u s
i m p l e m e n t a t i o n s
may e
d i s c u s s e d u s i n g a n
e x t e r n a l i n v e n t o r y
management s y s t e m
i n
W h i c h t h e s u p p l i e r s a r e e x t e r n a l
s u p p l i e r s .
T h i s i n v e n t i o n ,
h o W e v e r , i s n o t
l i m i t e d to
a n
e x t e r n a l i n v e n t o r y
management
s y s t e m
a n d
may i n c l u d e a n i n t e r n a l i n v e n t o r y
management
s y s t e m .
I n s t e a d ,
t h e
d i s c u s s i o n s
a r e
meant a s examples and
t h e
i n v e n t i o n
i s n o t l i m i t e d b y t h e
e x a m p l e s
p r e s e n t e d .
[ 0 0 4 2 ]
A l s o , i n
t h i s d o c u m e n t v a r i o u s i m p l e m e n t a t i o n s
may e
d i s c u s s e d u s i n g a s y n c h r o n o u s d y n a m i c l e a n r e p l e n
i s h m e n t a r r a n g e m e n t a n d / o r m e t h o d . T h i s i n v e n t i o n ,
hoW
e v e r ,
i s n o t
l i m i t e d t o a
s y n c h r o n o u s
dynamic e a n r e p l e n i s h
ment
arrangement a n d / o r method
and
may i n c l u d e an
a s y n c h r o n o u s d y n a m i c l e a n
r e p l e n i s h m e n t
a r r a n g e m e n t a n d /
o r
m e t h o d . As
i s c u s s e d h e r e i n , a
s y n c h r o n o u s
dynamic e a n
r e p l e n i s h m e n t
method
r e f e r s
t o
a n
i n v e n t o r y
management
s y s t e m t h a t i s b a s e d on c o n s u m p t i o n . A s a l s o d i s c u s s e d
h e r e i n , a n a s y n c h r o n o u s
d y n a m i c
l e a n r e p l e n i s h m e n t m e t h o d
r e f e r s t o an n v e n t o r y management system h a t i s based
on
a
s e t
time
n t e r v a l .
The
i s c u s s i o n s
a r e meant a s
examples
and
t h e i n v e n t i o n
i s n o t
l i m i t e d b y t h e e x a m p l e s p r e s e n t e d .
[ 0 0 4 3 ] I n
a n
embodiment f t h e
i n v e n t i o n ,
p r o j e c t e d i n v e n
t o r y
s t o c k may be
c a l c u l a t e d
based on h i s t o r i c a l demand
t r e n d s
a n d
r e p l e n i s h m e n t t r e n d s . Based
on demand
t r e n d s ,
p r o j e c t e d c o n s u m p t i o n o v e r
t h e
l e a d t i m e may
e
c a l c u l a t e d .
Based on r e p l e n i s h m e n t
t r e n d s , t h e
amount
o f
r e p l e n i s h e d
i n v e n t o r i e s W i t h i n a
l e a d t i m e
m a y be c a l c u l a t e d . A s d i s
c u s s e d h e r e i n ,
l e a d
t i m e
r e f e r s t o t h e amount f
t i m e
t h a t may
be
e q u i r e d
i n
o r d e r
t o
r e c e i v e
an r d e r .
[ 0 0 4 4 ] I n
a n e m b o d i m e n t ,
p r o j e c t e d
c o n s u m p t i o n
o v e r t h e
l e a d
time
may
e determined based
on
r a t e
of consumption
and a l e a d t i m e . A s d i s c u s s e d
h e r e i n ,
r a t e o f
consumption
r e f e r s t o t h e amount o f i n v e n t o r y t h a t may be consumed n
a
g i v e n
p e r i o d o f
t i m e . T o c a l c u l a t e e i t h e r r a t e
o f
c o n s u m p t i o n
o r l e a d t i m e ,
d i f f e r e n t
s t a t i s t i c a l
methods
may e e m p l o y e d .
Examples i n c l u d e , b u t a r e n o t
l i m i t e d
t o ,
a
moving a v e r a g e
m e t h o d ,
a
W e i g h t e d
moving a v e r a g e
m e t h o d ,
a n d a s i m p l e
l i n e a r
r e g r e s s i o n
m e t h o d .
[ 0 0 4 5 ] I n a n e m b o d i m e n t , t h e amount f
e p l e n i
s h e d
i n v e n
t o r i e s m ay
be
based on t h e amount
of
i n v e n t o r y
t h a t
i s
e x p e c t e d t o b e r e p l e n i s h e d W i t h i n
t h e
l e a d t i m e p e r i o d . T o
d e t e r m i n e
t h e amount, i n an embodiment, an o r d e r
method
may
e
employed i n Which t h e
amount
o n - o r d e r r e p r e s e n t s
t h e
amount f e p l e n i s h m e n t i n v e n t o r i e s t h a t
may
e r e c e i v e d
d u r i n g
t h e
l e a d t i m e .
I n
a n o t h e r e m b o d i m e n t ,
a
r u l e - b a s e d
o r d e r
method
may
b e
employed
i n
Which
t h e
amount
o f
r e p l e n i s h m e n t
i n v e n t o r i e s m a y
be
based on a set of system
r u l e s as de?ned by a consumer and s u p p l i e r s .
[ 0 0 4 6 ] I n a n e m b o d i m e n t ,
t h e
p r o j e c t e d i n v e n t o r y s t o c k
a t
t h e end o f l e a d t i m e may b e c a l c u l a t e d by
d e d u c t i n g
c o n
s u m p t i o n o v e r t h e l e a d
t i m e
a n d a d d i n g t h e
amount
f
e p l e n
i s h e d i n v e n t o r i e s
t o
c u r r e n t i n v e n t o r y
o n - h a n d .
With
a p r o
j e c t e d i n v e n t o r y s t o c k , t h e s y s t e m
i s
a b l e
t o
c o m p a r e t h e
p r o j e c t e d
i n v e n t o r y
s t o c k
a g a i n s t a s a f e t y
s t o c k
l e v e l . D i f f e r
e n t a c t i o n s
may
c c u r d e p e n d i n g upon
h e
c o m p a r i s o n .
[ 0 0 4 7 ] I n a n
e m b o d i m e n t ,
a p r o j e c t e d i n v e n t o r y s t o c k t h a t
i s
g r e a t e r
t h a n
o r
e q u a l t o
t h e
s a f e t y s t o c k may e q u i r e
t h a t
n o
r e p l e n i s h m e n t
s i g n a l
t o
b e s e n t to a
s u p p l i e r .
U n l i k e t h e p r i o r
a r t , a r e p l e n i s h m e n t
s i g n a l
i s
n o t s e n t
u n l e s s t h e p r o j e c t e d
-
8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
12/17
US 008/0215180
A 1
i n v e n t o r y s t o c k s l o w e r t h a n t h e s a f e t y s t o c k
t h u s
p r e v e n t i n g
u n n e c e s s a r y
h i g h i n v e n t o r y c a r r y i n g c o s t .
[ 0 0 4 8 ] I n a n e m b o d i m e n t , i f t h e p r o j e c t e d i n v e n t o r y s t o c k s
l e s s
t h a n
t h e s a f e t y
s t o c k ,
a
r e p l e n i s h m e n t s i g n a l may
e s e n t .
I n
an embodim ent,
a
r e p l e n i s h m e n t
s i g n a l
may
o t be
s e n t
i f
an empty b i n i s n o t a v a i l a b l e . I n a n o t h e r embodiment, t h e
number o f r e p l e n i s h m e n t
s i g n a l s
t h a t may b e s e n t may b e
based on t h e amount t h a t i s needed i n o r d e r t o m a k e t h e
p r o j e c t e d i n v e n t o r y s t o c k e q u a l
t o
t h e
s a f e t y s t o c k .
[ 0 0 4 9 ] T h e d y n a m i c l e a n
r e p l e n i s h m e n t
a r r a n g e m e n t a n d /
o r method,
i n
an embodiment,
may
n s u r e an optimum
e v e l
o f i n v e n t o r y
W i t h o u t i n c u r r i n g s t o c k
o u t . U n l i k e t h e
t r a d i
t i o n a l Kanban
s y s t e m , Which s b e s t a p p l i e d i n
a
c o n s i s t e n t
d e m a n d
e n v i r o n m e n t ,
t h e d y n a m i c l e a n
r e p l e n i s h m e n t
a r r a n g e m e n t may
a c c o m m o d a t e
? u c t u a t i n g d e m a n d s .
[ 0 0 5 0 ]
The
e a t u re s a n d a d v a n t a g e s o f
h e
p r e s en t i n v e n t i o n
may b e b e t t e r u n d e r s t o o d W i t h r e f e r e n c e t o t h e ? g u r e s and
d i s c u s s i o n s
t h a t
f o l l o W .
[ 0 0 5 1 ]
F I G .
3 s h o W s , i n
an
embodiment f t h e i n v e n t i o n , a
b l o c k d i a g r a m o f
a
d y n a m i c
l e a n
r e p l e n i s h m e n t
a r r a n g e m e n t .
A
onsumer 302
may
i n c l u d e
a p l u r a l i t y o f b i n s e . g . , b i n s
3 0 4 , 3 0 6 , 3 0 8 , a n d 3 1 0 ) . B i n s 3 0 4 , 3 0 6 , a n d
3 0 8
may
e p r e
s e nt
t h e
b i n s t h a t a r e
c u r r e n t l y
b e i n g e m p l o y e d b y company
3 0 2 .
Bin
310 may r e p r e s e n t an a d d i t i o n a l empty b i n t h a t
company
302
m ay a v e r e a d y
i n o r d e r to accommodate ?uc
t u a t i o n .
[ 0 0 5 2] I n an embodiment, t h e number
of
i n s
t h a t
a
con
sumer
m ay have a v a i l a b l e may
depend upon
an n i t i a l
a n a l y
s i s
o f h e
c o n s u m e r ’ s
h i s t o r i c a l demand r e n d . I n a n e x a m p l e ,
a
consumer’s
dema nd
i s t o r i c a l
t r e n d
has
s h o Wn
h a t
on aver
a g e 1 0 b i n s
m ay
be s u f ? c i e n t to
h a n d l e
t h e
d a i l y
d e m a n d s .
H o W e v e r , t h e
demand
h i s t o r i c a l t r e n d h a s a l s o
shoWn
t h a t
noW and
t h e n 30 i n s may be e q u i r e d i n o r d e r to h a n d l e t h e
? u c t u a t i o n i n demands.
A s
a r e s u l t , t h e consumer
may
l a c e
30
i n s on t s company ?oor and l l o n l y 1 0
b i n s .
The x t r a 20
b i n s may r e m a i n e m p t y u n t i l
c h a n g e s
i n
demand r e q u i r e
a d d i t i o n a l b i n s t o b e
? l l e d . T h i s method
o f a n t i c i p a t i n g
demand
i t h o u t
c a r r y i n g t h e i n v e n t o r y
c o t i s
a c o s t e f f e c t i v e
method
f
a d d r e s s i n g
? u c t u a t i o n i n
demands
h a t m i n i m i Z e s
t h e p o s s i b i l i t y
o f
a s t o c k - o u t
a n d /
r t h e p o s s i b i l i t y o f
h a v i n g
t o c o n s t a n t l y
r e s i Z e t h e
r e p l e n i s h m e n t l o o p
s i Z e .
[ 0 0 5 3 ]
C o n s i d e r t h e s i t u a t i o n W h e r e i n , f o r
e x a m pl e , b i n
3 0 4
h a s
b e e n c o n s u m e d . The d y n a m i c
l e a n r e p l e n i s h m e n t
s y s t e m
may i n c l u d e
a n i n t e l l i g e n c e 350 t h a t
i s
c a p a b l e o f
p e r f o r m i n g
a n a l y s i s
a n d
c a l c u l a t i n g t h e
p r o j e c t e d
i n v e n t o r y
s t o c k . I n a n embodiment, n t e l l i g e n c e 350 may be computer
s y s t e m t h a t m ay
i n c l u d e a
d a t a b a s e c a p a b l e o f
s t o r i n g con
s u m p t i o n e v e n t s a n d r e c e i p t e v e n t s o f r e p l e n i s h e d
m a t e r i a l s .
As
d i s c u s s e d
h e r e i n ,
p r o j e c t e d i n v e n t o r y s t o c k r e f e r s t o
a n
amount
f
n v e n t o r y s t o c k h a t s u b s t a n t i a l l y
m i n i m i Z e s
i n v e n
t o r y c a r r y i n g
c o s t
b u t p r e v e n t
s t o c k - o u t .
[ 0 0 5 4 ]
I f n t e l l i g e n c e 3 5 0 d e t e r m i n e s t h a t b i n 3 0 4 may a v e
t o
b e r e p l e n i s h e d i n
o r d e r t o
m e e t t h e
p r o j e c t e d i n v e n t o r y
s t o c k , t h e n a
s i g n a l
324 m ay e s e n t t o a s u p p l i e r 3 1 2 . Upon
r e c e i v i n g
t h e s i g n a l , s u p p l i e r 3
1 2
may
r o d u c e / p r o v i d e
m a t e
r i a l s
3 1 8 , Which
m a y
be e n t t o
consumer 302
o r e p l e n i s h b i n
3 0 4 .
[ 0 0 5 5 ]
H o W e v e r ,
a consumed i n
may
o t
a l W a y s
r e q u i r e
r e p l e n i s h m e n t
to o c c u r .
C o n s i d e r
t h e
s i t u a t i o n W h e r e i n ,
f o r
e x a m p l e ,
b i n 3 0 6 h a s b e e n c o n s u m e d . H o W e v e r , upon
n a l y
s i s ,
t h e
p r o j e c t e d i n v e n t o r y s t o c k h a s
b e e n
d e t e r m i n e d
t o
b e
met by
t h e
c o n s u m e r ’ s
c u r r e n t
i n v e n t o r y s t o c k . As
a
r e s u l t ,
e v e n
t h o u g h
b i n 306 a s
been
m p t i e d ,
t h e
b i n d o e s n o t h a v e
t o b e r e p l e n i s h e d .
S e p . 4 , 2 0 0 8
[ 0 0 5 6 ]
C o n s i d e r
a n o t h e r
s i t u a t i o n
W h e r e i n ,
f o r
e x a m p l e ,
more h a n one i n
m a y
have o be e p l e n i sh e d . I n an
example,
b i n
3 0 8
h a s
b e e n c o n s u m e d .
Upon a n a l y s i s , tWo b i n s may
h a v e
t o b e r e p l e n i s h e d
i n
o r d e r
t o meet t h e
p r o j e c t e d i n v e n
t o r y
s t o c k r e q u i r e m e n t .
I n t e l l i g e n c e
3 5 0
may
s e n d
a
s i g n a l
328 o a
s u p p l i e r
314 o r e p l e n i s h b i n 308 i t h m a t e r i a l s
3 2 2 .
I n a d d i t i o n , i n t e l l i g e n c e 3 5 0
may
d e n t i f y a
s e c o n d
b i n e . g . ,
b i n 3 0 6 ) t h a t may l s o h a v e t o b e r e p l e n i s h e d . T h u s , a s i g n a l
326
m ay have t o b e s e n t t o s u p p l i e r
314
t o r e p l e n i s h b i n
306
W i t h
m a t e r i a l s
3 2 0 .
[ 0 0 5 7 ]
F I G .
3
s h o W s
a s y n c h r o n o u s
d y n a m i c
l e a n r e p l e n
i s h m e n t
a r r a n g e m e n t .
H o W e v e r ,
t h e d y n a m i c l e a n r e p l e n i s h
m e n t
a r r a n g e m e n t may l s o b e
i m p l e m e n t e d
a s y n c h r o n o u s l y .
I n a n e x a m p l e , i n s t e a d
o f
p e r f o r m i n g a n
a n a l y s i s
e a c h
t i m e
When
c o n s u m p t i o n o c c u r s , a n a l y s i s
may b e p e r f o r m e d a t
p r e s e t t i m e i n t e r v a l s .
[ 0 0 5 8 ]
T h e d y n a m i c l e a n r e p l e n i s h m e n t
a r r a n g e m e n t
shoWn n F I G . 3 i s
an
example f hoW h e a r r a n g e m e n t m ay e
i m p l e m e n t e d i n o r d e r t o a c c o m m o d a t e t h e d y n a m i c c h a n g e s
i n
d e m a n d .
I n s t e a d
o f
a u t o m a t i c a l l y r e p l e n i s h i n g
e a c h
emp
t i e d b i n , t h e d y n a m i c l e a n r e p l e n i s h m e n t
a r r a n g e m e n t
a l l o W s
f o r a n a l y s i s
t o
be performed i n a t i m e l y manner n o r d e r
t o
c a l c u l a t e a
p r o j e c t e d i n v e n t o r y
s t o c k a n d
d e t e r m i n e
t h e
r e q u i r e d number f i n s t h a t may a v e to
b e
r e p l e n i s h e d . With
t h e d y n a m i c
l e a n
r e p l e n i s h m e n t
a r r a n g e m e n t ,
i n v e n t o r y c a r
r y i n g c o s t may b e s u b s t a n t i a l l y m i n i m i z e d a n d
s t o c k - o u t s
may e p r e v e n t e d .
[ 0 0 5 9 ]
F I G . 4 s h o W s , i n a n
embodiment
f t h e i n v e n t i o n , a
s i m p l e ?oW
h a r t
i l l u s t r a t i n g a d y n a m i c
l e a n
r e p l e n i s h m e n t
m e t h o d .
[ 0 0 6 0 ] At
a
? r s t
s t e p 4 0 2 , a b i n
state
i s o n - h a n d . I n an
e x a m p l e , t h e
b i n
i s
f u l l o f
a t e r i a l s
a n d c o n s u m p t i o n h a s n o t
o c c u r r e d .
[ 0 0 6 1 ] At t e p 4 0 4 , t h e b i n s consumed
n d
t h e
b i n
s t a t e i s
changed
o
e m p t y .
U n l i k e
t h e
p r i o r
r t ,
a n
empty
t a t e
may
o t
r e q u i r e a n i m m e d i a t e s i g n a l t o
b e
s e n t
t o
t h e s u p p l i e r f o r
r e p l e n i s h m e n t .
I n s t e a d , a n a l y s i s may e p e r f o r m e d n
o r d e r o
d e t e r m i n e t h e amount o f r e p l e n i s h m e n t
t h a t
may c c u r .
[ 0 0 6 2 ] A t s t e p 4 0 6 , a n a l y s i s
may
b e
p e r f o r m e d
a n d p r o
j e c t e d i n v e n t o r y
s t o c k
may
e
c a l c u l a t e d .
I n a n e m b o d i m e n t ,
t h e a n a l y s i s
may e p e r f o r m e d
a u t o m a t i c a l l y b y a c o m p u t e r
s y s t e m , Which
may
s t o r e c o n s u m p t i o n e v e n t s a n d r e c e i p t
e v e n t s
o f
r e p l e n i s h e d
m a t e r i a l s . The method f o r
a n a l y Z i n g
a n d c a l c u l a t i n g p r o j e c t ed i n v e n t o r y s t o c k i s d i s c u s s e d i n
d e t a i l s
i n t h e
l a t e r
? g u r e s .
[ 0 0 6 3 ] O n c e a n a l y s i s h a s
b e e n
p e r f o r m e d a n d
h e
p r o j e c t e d
i n v e n t o r y
h a s
b e e n d e t e r m i n e d , t h r e e a l t e r n a t i v e s a s s h o W n
i n s t e p s 4 0 8 , 4 1 0 , and 1 2 ) a r e a v ai l a b l e , i n
a n e m b o d i m e n t .
[ 0 0 6 4 ]
The method
may d e t e r m i n e t h a t , a t s t e p
4 0 8 , n o
a c t i o n
i s
n e e d e d
s i n c e t h e
p r o j e c t e d i n v e n t o r y s t o c k h a s
b e e n
d e t e r m i n e d t o be t a s u ? i c i e n t l e v e l (enough s a f e t y s t o c k t o
h a n d l e
u n e x p e c t e d s p i k e s ) .
I n
a n
e x a m p l e ,
t h e b i n t h a t
i s
c u r r e n t l y
i n
a n
empty t a t e a s
d e s c r i b e d i n s t e p 4 0 4 ) i s n o t
i m m e d i a t e l y r e p l a c e d b e c a u s e t h e
company h a s s u f ? c i e n t
s a f e t y
s t o c k
a n d / o r
demand may e c u r r e n t l y
d e c l i n i n g .
[ 0 0 6 5 ] A l t e r n a t i v e l y , a t s t e p
4 1 0 ,
t h e method may
d e t e r
mine
h a t t h e c u r r e n t
empty
i n ( f r o m
s t e p
4 0 4 )
may
e e d
o
b e
r e p l e n i s h e d .
[ 0 0 6 6 ] A l t e r n a t i v e l y , a t
a
n e x t
s t e p
4 1 2 ,
t h e
method
may
d e t e r m i n e
h a t
n o t o n l y d o e s
t h e c u r r e n t empty i n
( f r o m s t e p
4 0 4 ) need
o
be e p l e n i s h e d b u t
one
r more empty i n s may
a l s o n e e d
o
b e
r e p l e n i s h e d s i n c e demand s r i s i n g a n d / o r t h e
s a fe t y s t o c k
i s
i n s u ? i c i e n t .
-
8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
13/17
US 008/0215180
A 1
[ 0 0 6 7 ]
I f
t h e method
e t e r m i n e s
t h a t
e i t h e r
s t e p 410 r
s t e p
412 b e s t d e s c r i b e s t h e c o n s u m e r ’ s c u r r e n t
s i t u a t i o n ,
a t
s t e p
4 1 4 ,
one
o r
m o r e
replenishment
s i g n a l s may
be
s e n t t o a
s u p p l i e r .
Upon
s e n d i n g t h e s i g n a l , t h e b i n
h a t
i s i m p a c t e d s
changed fr om an
empty
s t a t e t o
an
on-order
t a t e .
[ 0 0 6 8 ] At n e x t
s t e p
4 1 6 , t h e s u p p l i e r r e c e i v e s t h e
r e q u e s t .
[ 0 0 6 9 ]
At
a n e x t s t e p
4 1 8 ,
t h e s u p p l i e r h a n d l e s t h e
r e q u e s t .
[ 0 0 7 0 ] At a n e x t s t e p 4 2 0 , t h e s u p p l i e r s e n d s t h e m a t e r i a l s
t o the consumer.
[ 0 0 7 1 ] At
a
l a s t s t e p 4 2 2 ,
t h e
consumer
e c e i v e s t h e
mate
r i a l s and
one
or
m o r e
b i n s a r e ? l l e d . Once
t h e
bin has
been
r e p l e n i s h e d , t h e
b i n
s t a t e may e c h a n g e d f r o m o n - o r d e r to
o n - h a n d .
[ 0 0 7 2 ] The method d e s c r i b e d
i n
s t e p s
402 t o
422
i s
an
i t e r a t i v e
process t h a t occurs a s bins a r e
consumed.
[ 0 0 7 3 ] F I G .
5
s h o W s , i n a n embodiment o f t h e
i n v e n t i o n ,
s i m p l e
d i a g r a m
i l l u s t r a t i n g t h e
d i f f e r e n t
b i n s t a t e s
i n
a
d y n a m i c
l e a n
r e p l e n i s h m e n t
s y s t e m .
[ 0 0 7 4 ] At state
5 5 0 ,
t h e b i n h a s a state of n - h a n d . I n an
e x a m p l e ,
t h e b i n h a s b e e n ? l l e d a n d c o n s u m p t i o n h a s n o t
o c c u r r e d .
[ 0 0 7 5 ] At t e p 5 5 2 , t h e
b i n
i s c o n s u m e d .
[ 0 0 7 6 ]
At
t a t e
5 5 4 ,
t h e b i n s t a t e
i s
c h a n g e d f r o m
o n - h a n d
to
e m p t y .
[ 0 0 7 7 ] At
a
n e x t s t e p 5 5 6 , a n a l y s i s i s p e r f o r m e d .
W i t h
a n a l y s i s , t h e p r o j e c t e d i n v e n t o r y s t o c k may
e
c a l c u l a t e d a n d
t h e
number
f a d d i t i o n a l b i n s
r e q u i r e d
s i d e n t i ? e d .
A s
f o r e
m e n t i o n e d , more e t a i l s W i l l b e p r o v i d e d f o r t h e a n a l y s i s i n
l a t e r
? g u r e s .
[ 0 0 7 8 ]
I f t a
n e x t
s t e p
5 5 8 ,
t h e
number
f a d d i t i o n a l
b i n s
t h a t
may ave
o be e p l e n i s h e d i s Z e r o o r l e s s ,
then t
a
n e x t
s t e p 5 6 0 , no a c t i o n m ay e
needed and
t h e b i n m ay remain
e m p t y .
[ 0 0 7 9 ]
H o W e v e r ,
i f a t n e x t s t e p 5 5 8 , t h e number o f a d d i
t i o n a l b i n s t h a t h a v e t o b e r e p l e n i s h e d
i s
g r e a t e r
t h a n
Z e r o ,
t h e n
t
s t e p
5 6 2 ,
a n
o r d e r
s
p l a c e d
W i t h
a
s u p p l i e r ,
Which
may
i n c l u d e s e n d i n g
a
s i g n a l t o
t h e s u p p l i e r
r e q u e s t i n g f o r
a
b i n
to
be
e ? l l e d .
[ 0 0 8 0 ]
Once
h e o r d e r h a s b e e n p l a c e d ,
a t s t e p
5 6 4 , t h e
b i n
s t a t e i s changed from empty o
o n - o r d e r .
[ 0 0 8 1 ] At
ste p
5 6 6 ,
t h e number o f
b i n s
n e e d e d may b e
r e d u c e d
by
o n e .
[ 0 0 8 2 ]
The methods
f o r
p l a c i n g
a n
o r d e r
W i t h a s u p p l i e r a s
d e s c r i b e d i n s t e p s 558 o
566
m a y be an t e r a t i v e p r o c e s s u n t i l
t h e number
o f
b i n s
needed
t o
b e
r e p l e n i s h e d based on t h e
p r o j e c t e d i n v e n t o r y s t o c k
number h a s
been m e t . I n an
e m b o d i m e n t ,
t h e
d y n a m i c
l e a n
r e p l e n i s h m e n t
s y s t e m
may
e n a b l e more than one i n
t o be
ordered i n c e
a d d i t i o n a l
empty
b i n s a r e
a v a i l a b l e .
I n
an
x a m p l e , empty i n s may e v a i l a b l e
due
o
b i n s
t h a t m ay a v e been
r e v i o u s l y
consumed
u t
n o t
r e p l e n i s h e d d u e t o t h e
p r o j e c t e d i n v e n t o r y s t o c k
r e q u i r e m e n t
a t
t h e
t i m e . I n
a n o t h e r e x a m p l e , t h e
company
m ay
have
s e t
a s i d e 30
b i n s
b u t may o t
have needed t o
? l l more
t h a n
10
b i n s . H o W e v e r ,
W i t h
t h e c u r r e n t pr o j e c t e d i n v e n t o r y s t o c k
r e q u i r e m e n t ,
one
r more
of
h e c u r r e n t l y empty
20
i n s
m a y
b e r e p l e n i s h e d .
[ 0 0 8 3 ] At s t e p 5 6 8 , t h e m a t e r i a l s a r e r e c e i v e d by t h e con
sumer
and
t h e b i n i s r e ? l l e d . The method e s c r i b e d i n s t e p s
550 t o 568 i s an
i t e r a t i v e
p r o c e s s and
m a y be employed
t o
a c c o m m o d a t e
d a i l y ? u c t u a t i o n s .
[ 0 0 8 4 ]
F I G .
4
a n d
5
a r e
e x a m p l e s o f t h e dynamic l e a n
r e p l e n i s h m e n t
method. A s can
be
s e e n , t h e
method m a y
o t
a u t o m a t i c a l l y r e q u i r e a consumed b i n t o b e r e p l e n i s h e d .
I n s t e a d ,
t h e method may
i m p l e m e n t a n i n t e l l i g e n c e
t h a t i s
c a p a b l e o f
a n a l y Z i n g a
c o m p a n y ’ s demand
a t t e r n
t o
d e t e r
mine
When
e p l e n i s h m e n t
m a y
need o o c c u r .
S e p . 4 , 2 0 0 8
[ 0 0 8 5 ]
F I G .
6 s h o W s , i n a n embodiment f t h e i n v e n t i o n , a
s i m p l e ?oW h a r t
i l l u s t r a t i n g
a n e x a m p l e o f
hoW
n a l y s i s a n d
c a l c u l a t i n g
t h e
p r o j e c t e d i n v e n t o r y s t o c k a s
s h o W n
i n s t e p s
4 0 6
a n d 5 5 6 ) may e
p e r f o r m e d .
[ 0 0 8 6 ]
At
t e p
6 0 2 , t h e
method
d e n t i ? e s t h e c u r r e n t
i n v e n
t o r y o n - h a n d . C o n s i d e r t h e s i t u a t i o n W h e r e i n , f o r
e x a m p l e ,
a
company
a s
1 0
b i n s
a v a i l a b l e o n - h a n d . Once
a b i n
h a s been
c o n s u m e d , t h e s y s t e m may h e c k a d a t a b a s e , f o r e x a m p l e ,
t o
determine
hoW many
i n s
a r e
a v a i l a b l e . I n
an embodiment,
n
a n
a s y n c h r o n o u s
d y n a m i c l e a n r e p l e n i s h m e n t a r r a n g e m e n t ,
i n s t e a d o f
p e r f o r m i n g a n a l y s i s
e a c h t i m e c o n s u m p t i o n
o c c u r s ,
a n a l y s i s may e p er f o r m e d a t
a p r e s e t
t i m e
i n t e r v a l .
[ 0 0 8 7 ] At a n e x t s t e p
6 0 4 ,
p r o j e c t e d c o n s u m p t i o n
may
e
s u b t r a c t e d
from
t h e c u r r e n t i n v e n t o r y
o n - h a n d . As d i s c u s s e d
h e r e i n , p r o j e c t e d c o n s u m p t i o n e f e r s t o
t h e amount
f
i n v e n
t o r i e s e . g . ,
b i n s ) t h a t may e
consumed u r i n g t h e
l e a d t i m e .
T o d e t e r m i n e
p r o j e c t e d
c o n s u m p t i o n , a
r a t e
o f c o n s u m p t i o n
and
a l e a d time may e
c a l c u l a t e d .
[ 0 0 8 8 ]
I n
an embodiment, a r a t e
o f
consumption may
b e
based on
moving
average
method.
I n
an
example,
t h e
com
pany m ay e t e r m i n e t h a t
t h e
r a t e of consumption s based
on
a n a v e r a g e
o f
h e
l a s t
1 0
d a y s . F o r
e x a m p l e ,
d u r i n g t h e
l a s t
1 0
d a y s ,
30
i n s
may a v e
been consumed.
T h u s , a n a v e r a g e o f
3 b i n s h a s b e e n
consumed
a c h d a y . The a t e o f c o n s u m p t i o n
i s
t h e n compared to t h e m a x i m u m and minimum r a t e s o f
c o n s u m p t i o n . The m a x i m u m and m ini m u m r a t e s o f con
s u m p t i o n may e employed
n
o r d e r t o p r e v e n t
a n
i n d e ? n i t e
i n c r e a s e i n i n v e n t o r y a n d / r a d r o p i n i n v e n t o r y l e v e l t h a t
may
c a u s e s t o c k - o u t .
As su me
n t h i s
e x a m p l e , t h a t
t h e m a xi m u m
r a t e o f o n s u m p t i o n s 4
b i n s p e r
day and
h e
minimum ate o f
c o n s u m p t i o n i s l
b i n p e r
d a y .
S i n c e t h e r a t e
o f
c o n s u m p t i o n
e . g . ,
3
b i n s )
i s
b e t W e e n
t h e
minimum
and
maximum
a t e s o f
c o n s u m p t i o n
e . g . ,
l
b i n a n d 4 b i n s , r e s p e c t i v e l y ) , t h e r a t e o f
consumption m ay be s e t t o
t h e c a l c u l a t e d a v e r a g e
r a t e of
c o n s u m p t i o n . H o W e v e r ,
i f
t h e
r a t e
o f c o n s u m p t i o n s
g r e a t e r
t h a n t h e m a x i m u m r a t e o f c o n s u m p t i o n , th e n t h e r a t e o f
consumption
may
e
s e t
t o t h e
m a x i m u m ate o f
o n s u m p t i o n
e . g . , 4 b i n s ) . L i k e w i s e ,
i f
t h e r a t e o f c o n s u m p t i o n s l e s s t h a n
t h e
m ini m u m
a t e o f
c o n s u m p t i o n , t h e n
t h e r a t e o f consump
t i o n may be e t to t h e minimum ate o f consumption
e . g . ,
l
b i n ) .
[ 0 0 8 9 ]
The moving
a v e r a g e
method s a s l i d i n g WindoW
method h a t t a k e s i n t o a c c o u n t c h a n g i n g
c o n d i t i o n s b u t
a t
t h e
same t i m e
g i v e s
l i t t l e o r no W e i g h t to consumption t h a t h a s
o c c u r r e d
beyond de?ned i m e
p e r i o d .
I n a n e x a m p l e , i f t h e
i n i t i a l
t i m e
p e r i o d o f a n a l y s i s
i s
f r o m J u n e
1 t o
J u n e
1 4 , t h e
n e x t
d a y
a n a l y s i s may
e
f r o m J u n e 2 t o J u n e 1 5 . T h u s , o n l y
t h e most r e c e n t c o n s u m p t i o n d a t a may e employed n
c a l
c u l a t i n g t h e m o v i n g a v e r a g e .
[ 0 0 9 0 ] I n
a n e m b o d i m e n t , a W e i g h t e d
moving
a v e r a g e
method
may
b e
employed
i n s t e a d
o f
a
moving
a v e r a g e
m e t h o d . The W e i g h t e d moving a v e r a g e method s
s i m i l a r
t o
t h e moving a v e r a g e
method
e x c e p t d i f f e r e n t W e i g h t s may e
a p p l i e d
t o t h e d a t a
d e p e n d i n g
upon r e l e v a n c y
e . . ,
more
r e c e n t d a t a
v s . l e s s
r e c e n t
d a t a ) .
[ 0 0 9 1 ]
I n a n o t h e r e m b o d i m e n t ,
a
r a t e
o f
c o n s u m p t i o n
may
be
a l c u l a t e d b a s e d
on
a s i m p l e l i n e a r r e g r e s s i o n method. I n
t h i s m e t h o d , consumption v e r
a de?ned
i m e p e r i o d
may e
c o l l e c t e d and l o t t e d
on g r a p h . L i n e a r r e g r e s s i o n m ay c c u r
i n Which t h e d a t a p l o t t e d may b e a p p r o x i m a t e d
i n
o r d e r t o
d e t e r m i n e
a
t r e n d
l i n e .
A l o p e
and
n t e r c e p t
may
e c a l c u
l a t e d
b a s e d
on
h e p l o t t e d
h i s t o r i c a l d a t a .
With h e s l o p e
a n d
i n t e r c e p t , a p r o j e c t e d r a t e o f
c o n s u m p t i o n may b e
d e t e r
m i n e d .
The l o p e
a n d i n t e r c e p t method
s
W e l l - k n o w n to t h o s e
s k i l l e d i n
t h e
a r t .
T h u s , no u r t h e r d i s c u s s i o n W i l l be r o v i d e d .
-
8/19/2019 Arrangement for Dynamic Lean Replenishment and Methods Therefor
14/17
US 008/0215180
A 1
[ 0 0 9 2 ]
The
t h r e e methods
d e s c r i b e d
a b o v e a r e o n l y
e x a m p l e s o f
t h e m e t h o d s t h a t may e
employed
o c a l c u l a t e
t h e r a t e o f c o n s u m p t i o n .
[ 0 0 9 3 ] B e s i d e s t h e
r a t e o f c o n s u m p t i o n ,
t h e l e a d t i m e may
a l s o
be
c a l c u l a t e d .
A s
d i s c u s s e d
h e r e i n ,
a l e a d
t i m e
r e f e r s t o
t h e
t i m e
i n t e r v a l an
r d e r
m a y be u l ? l l e d
by
s u p p l i e r .
I n
an
e m b o d i m e n t , o n e method f o r d e t e r m i n i n g
t h e
l e a d t i m e i s
based
on
s e t v a l u e .
I n
an example,
a
s e t
value
of days may
have been
e s t a b l i s h e d
a s
t h e l e a d
t i m e . T h u s ,
t h e
company
may
s s ume h a t an
r d e r
t o
? l l
an empty bin
may
a k e
6 days
to be
e c e i v e d .
[ 0 0 9 4 ]
I n
a n o t h e r e m b o d i m e n t , a method f o r c a l c u l a t i n g
t h e
l e a d
t i m e m ay be a s e d
on
i s t o r i c a l r e p l e n i s h m e n t t r e n d .
I n a n
e x a m p l e ,
a moving
a v e r a g e m ay be employed
o c a l c u
l a t e t h e h i s t o r i c a l l e a d t i m e .
I n
a n e x a m p l e , t h e company m ay
d e t e r m i n e t h a t l e a d t i m e may be based
on
h e a v e r a g e
r e p l e n
i s h m e n t t i m e p e r i o d f o r t h e l a s t 1 0 o r d e r s . F o r e x a m p l e ,
d u r i n g
t h e l a s t 1 0 o r d e r s , 5 0 d a y s
may a v e
b e e n r e q u i r e d t o
r e c e i v e
a l l 1 0
o r d e r s . T h u s ,
on
a v e r a g e , a
s h i p m e n t
m ay
be
r e c e i v e d i n 5 d a y s f r o m t h e d a t e o f r d e r . A l t h o u g h d a y s a r e
b e i n g e m p l o y e d , t i m e
i n t e r v a l
may
b e
e x p r e s s e d
i n
h o u r s ,
m i n u t e s ,
W e e k s ,
a n d
t h e
l i k e s . The i m e i n t e r v a l may h a n g e
d e p e n d i n g
upon
h e
c o n s u m e r ’ s
n e e d s .
[ 0 0 9 5 ] S i m i l a r o
t h e
r a t e o f o n s u m p t i o n ,
t h e
moving v e r
a g e
may
e W e i g h t e d . I n a n
e x a m p l e ,
d i f f e r e n t W e i g h t s
may
b e
a p p l i e d
t o
t h e
d a t a d e p e n d i n g
upon e l e v a n c y
e . g . ,
more
r e c e n t d a t a v s . l e s s r e c e n t
d a t a ) .
[ 0 0 9 6 ] I n
a n o t h e r e m b o d i m e n t , t h e
l e a d t i m e
may e
c a l
c u l a t e d b a s e d on a s i m p l e l i n e a r r e g r e s s i o n m e t h o d .
I n
t h i s
m e t h o d , r e p l e n i s h m e n t t i m e p e r i o d
f o r
a
p r e d e t e r m i n e d
num
b e r
o f o r d e r s m ay be
o l l e c t e d
and
l o t t e d on
g r a p h . L i n e a r
r e g r e s s i o n may o c c u r i n Which t h e d a t a p l o t t e d may b e
a p p r o x i m a t e d i n
o r d e r to
d e t e r m i n e
a t r e n d
l i n e . A
l o p e
and
i n t e r c e p t may
b e
c a l c u l a t e d
b a s e d
on
t h e p l o t t e d h i s t o r i c a l
d a t a . With h e s l o p e a n d i n t e r c e p t , a p r o j e c t e d l e a d
t i m e may
be d e t e r m i n e d .
[ 0 0 9 7 ]
Once
h e
a t e
o f o n s u m p t i o n
a n d
t h e l e a d
t i m e
h a v e
b e e n d e t e r m i n e d , p r o j e c t e d c o n s u m p t i o n o v e r t h e l e a d t i m e
may
be a l c u l a t e d . I n a n e x a m p l e , t h e r a t e o f consumption s
3 b i n s p e r
d a y a n d
t h e l e a d t i m e i s 5 d a y s . To
c a l c u l a t e
t h e
p r o j e c t e d
c o n s u m p t i o n , t h e
r a t e
o f
c o n s u m p t i o n may e m u l
t i p l i e d b y t h e l e a d t i m e .
P r o j e c t e d
c O n S u I n p t i O n I R a t e
o f
c o n s u r n p t i o n x L e a d
t i m e
P r o j e c t e d c o n s u r n p t i o n : 3 > < 5
P r o j e c t e d c o n s u r n p t i o n : l 5 b i n s
[ 0 0 9 8 ] E q u a t i o n 1 a b o v e s h o W s a n e x a m p l e o f a
p r o j e c t e d
c o n s u m p t i o n c a l c u l a t i o n . Based on
t h e
c a l c u l a t i o n ,
l 5
b i n s
may
be consumed
i t h i n t h e
n e x t
5
d a y s .
T h u s , t h e
amount
o
b e
consumed
i t h i n
t h e l e a d
t i m e
i s
t h e c a l c u l a t e d p r o j e c t e d
c o n s u m p t i o n .
[ 0 0 9 9 ] I n
an
embodiment, same o r d i f f e r e n t s t a t i s t i c a l
method
may
e
employed
n c a l c u l a t i n g
t h e r a t e o f
consump
t i o n a n d t h e
l e a d
t i m e . I n a n e x a m p l e , i f t h e
W e i g h t e d
moving
a v e r a g e
method
a s
been
employed
t o c a l c u l a t e t h e r a t e o f
c o n s u m p t i o n ,
t h e n
a s i m p l e moving a v e r a g e method
may
e
employed o
c a l c u l a t e
t h e l e a d
t i m e .
[ 0 1 0 0 ] A t
a
n e x t s t e p 6 0 6 , t h e i n v e n t o r y e . g . , b i n s ) t h a t may
be
r e c e i v e d d u r i n g t h e l e a d
t i m e
may
be
added
t o
c u r r e n t
i n v e n t o r y
o n - h a n d . D i f f e r e n t m e t h o d s may
b e
employed o
d e t e r m i n e
t h e amount
f
e p l e n i s h e d i n v e n t o r y . I n an embodi
m e n t ,
t h e
o r d e r method may
b e e m p l o y e d . With t h e
o r d e r
m e t h o d ,
t h e a m o u n t
o f
e p l e n i s h e d i n v e n t o r y t h a t i s
c u r r e n t l y
o n - o r d e r s
assumed
o b e
r e c e i v e d by h e
company i t h i n
t h e
E q u a t i o n 1
S e p . 4 , 2 0 0 8
l e a d
t i m e .
I n
a n e x a m p l e , i f 1 6
b i n s a r e
c u r r e n t l y o n - o r d e r ,
t h e n t h e amount f
r e p l e n i s h e d
i n v e n t o r y i s 1 6 b i n s .
[ 0 1 0 1 ] I n
a n o t h e r
embodiment, a r u l e - b a s e d o r d e r method
may b e e m p l o y e d . W i t h
t h e
r u l e - b a s e d o r d e r m e t h o d ,
t h e
amount
of
e p l e n i s h e d i n v e n t o r y
m a y
be based
on
a
set
of
s y s t e m r u l e s ,
Which
may
e
d e p e n d e n t
upon When a n o r d e r
m ay a v e been p l a c e d W i t h
a
s u p p l i e r .
I n
an e x a m p l e ,
i f
a n
o r d e r
i s p l a c e d
b e f o r e
a
c e r t a i n d a t e
t h e n t h e
o r d e r
m ay be
f u l ? l l e d
W i t h i n
a c e r t a i n
number f
d a y s and t h e r e f o r e ,
may
be r e c e i v e d W i t h i n t h e
l e a d t i m e .
HoWever, i f an
o r d e r
i s
p l a c e d
a f t e r
a
c e r t a i n
d a t e o r
t i m e t h e n
t h e o r d e r may o t
be
f u l ? l l e d i m m e d i a t e l y and
may
o t b e r e c e i v e d by
t h e com
pany i t h i n t h e
l e a d
t i m e . I n
an x a m p l e ,
i f
an
r d e r
s p l a c e d
W i t h a s u p p l i e r
b e f o r e
W e d n e s d a y ,
t h e n
t h e o r d e r W i l l b e
h a n d l e d on T h u r s d a y .
H o W e v e r , i f
a n o r d e r i s p l a c e d a f t e r
Wednesday, t h e n t h e o r d e r
W i l l
n o t b e h a n d l e d
u n t i l
n e x t
M o n d a y . C o n s i d e r t h e s i t u a t i o n W h e r e i n , f o r e x a m p l e , o f t h e
1 6 b i n s o n - o r d e r , o n l y 9 b i n s
may a v e
b e e n o r d e r e d p r i o r
t o
W e d n e s d a y .
The
u l e - b a s e d
o r d e r
m e t h o d , i n a n e m b o d i m e n t ,
may e
p r e - s e t b a s e d on
g