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A technique for laying out warehouse storage which seeks to minimize “pick” travel time by grouping the most used items closest to their point of use.
Dr. Shewhart was a prominent scientist with the Western Electric Engineering Department back in the 1920s. In 1924, Dr. Shewhart devised a framework for the first application of the statistical method to the problem of quality control. Shewhart wrote a note to R.L. Jones, responding to his request for some type of inspection report that “might be modified from time to time, in order to give a glance at the greatest amount of accurate information”. He attached a sample chart “designed to indicate whether or not the observed variations in the percent of defective apparatus of a given type are significant; that is, to indicate whether or not the product is satisfactory.”
Shewhart’s example was the world’s first schematic control chart. In one short letter, he had set forth the essential principles and considerations of quality control. As he pursued this work, Shewart gave birth to the modern scientific study of statistical process control. In 1931, Shewhart’s book ‘Economic Control of Quality of Manufactured Product’ contained his findings on statistical sampling techniques. A Western Electric colleague, W. Edwards Deming, spread the word on Shewhart’s work when he joined the US War Department, and later when he taught the fundamentals of quality in Japan.
Taylor, Frederick Winslow (1856-1915), American industrial engineer, who originated scientific management in business. He was born in Germantown (now part of Philadelphia), Pennsylvania. In 1878, he began working at the Midvale Steel Company. He became foreman of the steel plant and applied himself to studies in the measurement of industrial productivity. Taylor developed detailed systems intended to gain maximum efficiency from both workers and machines in the factory. These systems relied on time and motion studies, which help determine the best methods for performing a task in the least amount of time. In 1898 he became joint discoverer of the Taylor-White process, a method of tempering steel. Taylor served as consulting engineer for several companies. His management methods were published in The Principles of Scientific Management.
A standard approach for creating a new production facility layout for either a green field or an existing facility is as follows:
PQ (Product Quantity Pareto ABC Analysis) and Product Process (find common routings in a mixed model business) are defined elsewhere. For many practitioners Block Layout seems be be either a bit of artistry or is mired in software complexities. Here are a few thoughts on how to approach this step in the facility design process. First a few considerations: In a green field we know the product and process and want to determine the size of the building we need and it’s layout. For a brown field we’re trying to make the best use of the use of the four walls we already have. In both scenarios there are trade offs to make. Having a decision making at the beginning of the project can save a lot of time and money. Some will take a mathematical approach, others organic consensus. Either way agree on the design process methodology up front. Determine “best” layout type based on customer demand, product and processing characteristics, and business strategy. Common layout types include:
In brown field facilities the main layout consideration is often in fact moving from one layout type to another as business conditions and strategies evolve. Determine the activity and proximity relationships between the various blocks. A great approach for understanding relationships is the Simplified Systematic Layout Planning method by Muther and Wheeler.
The number of permutations can be huge, so either use group intuition for the block details or investing in one of the current software packages such as Pro Planner, PlanOpt, Flow Planner.
First listed various formulations of calculating kanban quantities in July 2006. Here are a few more … 9. wmarhel at Elsmar Cove writes … The formula for calculating the number of kanban cards in a system for a particular product is: (Daily Demand x (Run Frequency + Lead Time + Safety Time)) / Container Capacity Where: Daily Demand = Customer Consumption expressed as # of units 10. World Class Manufacturing has an on-line Kanban Size Calculator that uses the following formula: Total Required Inventory (TRI) = Weekly Part Usage * Lead-time * Number of locations for stock 11. Oracle uses By default, the standard calculation is: (C – 1) * S = D * L where:
12. SAP says … K = ((RT * AC)/CONT) * (SF + C) where
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