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Key Features of QAD Lean Manufacturing

  • Ability to communicate Kanban status throughout the supply chain
  • Enable enhanced lean manufacturing techniques (average demand calculation, supermarket and sizing logic, dynamic safety stock)
  • Manage inventory buffer (supermarket) through Kanbans and enforcement of pull replenishment
  • Enhanced Kanban transaction processing
  • Card tracking includes both authorization date and expected due date
  • Facilitates workbench simulations (sizing inventory buffers, determining Kanbans and Kanban quantities for each loop, analyzing product mix, developing leveled schedule at pacemaker process)
  • Advanced logic for Every-Part, Every-Item (EPEI) calculations

Kanban

  • Enter transactions to record purchase receipts, item movement and production receipts of Kanban-controlled items
  • Menu-level programs track individual states for each Kanban card (post/consume, authorize, acknowledge, ship and fill/receive actions)
  • Set up Kanban loops with automatic accumulators based on order quantity or specified time intervals
  • Transact Kanban cards via barcode scanners or direct entry
  • Electronic Kanban boards provided as part of dispatching functionality and Kanban Visualization
  • Update cards/send dispatch list via EDI-enabled functionality
  • Fill supplier Kanbans individually and generate purchase order receipts, or process a single PO Shipper Receipt for the total quantity, updating all appropriate Kanban cards and Advance Ship Notices (ASN)

Kanban

Kanban Master Maintenance provides all needed information for Kanban controlled items

Supermarket Management

  • Enables users to tightly manage amount of inventory within the value stream to allow for a pull system
  • Supermarkets are also referred to as inventory buffers and can contain either finished items or work in process
  • Provides for multiple methods of calculating and setting supermarket quantities based on either manual data entry or system calculations that include a variety of flexible, user-defined parameters

Average Demand Calculations

  • Provides help in automatically determining recommended supermarket size, number of Kanbans and the quantity of a Kanban in a loop and safety stock
  • Uses various combinations of actual historical and projected future demand in a flexible environment

Safety Stock Calculations

QAD Lean Manufacturing provides a variety of ways to specify safety stock, including the following:

  • The quantity and number of days that the system uses in combination with average demand calculations to determine a number
  • Specify an automatic calculation based on a desired service level and the calculated demand variability (standard deviation)
  • On peak demand during a user-specified period

 

Safety Stock Calculations

Kanban Workbench allows evaluation of key statistical values for each item

Every Product, Every Interval (EPEI) Calculations

  • Helps to determine the manufacturing lot size and supermarket quantities for each part produced in a particular manufacturing process, as well as the number of Kanban cards in the replenishment loop
  • Provides several mechanisms, including a comprehensive Kanban Workbench, for calculating the EPE Interval

Simulated Kanban Calculations

  • Enables users to work with the EPE Interval, packaging or logistics constraints to receive preliminary Kanban quantities
  • Enables users to set an appropriate Kanban size based on real-world experience with actual Kanbans
  • Users can re-run Kanban Workbench using updated historical demand data and revise the number of cards, inactivate or reactivate cards as needed.
    • Extensive card reconciliation capabilities for adding and removing Kanban cards from loops can be driven from inside the workbench or run as stand alone functions
    • For downsizing loops, the user has additional controls for how cards are taken out of the loop
  • Users can adjust both Replenishment (Production) Kanbans or Move Kanbans based on the sizing calculations

Kanban Calculations

Kanban Workbench provides data specific to an overall process

Mix Analysis and Load Leveling

Level Mix Workbench can be used to perform five major functions for your pacemaker processes:

  • Calculate the volume of all parts that must be run each day
  • Determine the mix of various items produced in the process
  • Calculate a suggested daily level schedule by shift for each item based on the established process volume, mix, pitch, EPEI and the product wheel
  • Evaluate schedule and buffer performance for each item using the Supermarket Evaluation
  • Update the master production schedule

Takt Time Calculation

  • Represents the customer demand rate and is used to synchronize the rate of production with the rate of sales
  • Key input to operator loading and balancing calculations
  • Used as the basis for Operational Takt Time, which includes inventory buffer adjustments

Flow Scheduling

  • Provides the ability to generate time-phased sequence statements of production requirement for production lines in a flow manufacturing environment
  • Offers the ability to decrease inventory, lot sizes and cumulative product lead times, reduce non-value add activities and increase customer satisfaction levels
  • Flow Schedule Maintenance provides additional scheduling and capacity planning capabilities

Communicate Kanban Status throughout the Supply Chain with QAD Supply Chain Portal

  • Provides near real-time visibility into electronic Kanban signals inside the customer’s facility and to selected suppliers
  • Allows internal production lines and suppliers to closely monitor how items are being consumed and respond to replenishment signals
  • Available through the MFGx.net manufacturing community
  • A poller is installed to obtain data from QAD Lean Manufacturing to display Kanban information to the supplier through a browser (either Internet Explorer or Netscape)
  • Customers do not need to make any modifications to the existing corporate firewall; if it is possible to browse the Internet from within the company, it is possible to use QAD Supply Chain Portal with Kanban functionality
  • Supports QAD Lean Manufacturing in QAD Enterprise Applications 2007