Presentation on theme: "Scenario Overview – 1 Purpose and Benefits: Purpose Benefits"— Presentation transcript:
1 Lean Manufacturing - Heijunka Leveling SAP Best Practices for Automotive Package (Japan)
2 Scenario Overview – 1 Purpose and Benefits: Purpose Benefits The scenario shows how existing tools and functions of the SAP ERP portfolio can be used to convert uneven customer pulls into an even and predictable manufacturing schedule (Heijunka leveling) to enable upstream Kanban supply with SAP Kanban tools according to lean Toyota Production System (TPS) principles , it focuses on a lean production control method within a repetitive manufacturing environment: using Kanban processing for lean replenishment.BenefitsHeijunka technique levels uneven customer demands to even production schedule on final assembly line, subsequently, production process at a constant and predictable rate prevents waste caused by the fluctuations in performance.To adopt sequence schedule with setup time optimization instead of equally distribution dispatching, it gets more efficient to avoid muda (waste).Just in time delivery via Kanban pull fulfills lean planning and manufacturing principles.
3 Scenario Overview – 2 SAP Applications Required: Enhancement Package 4 for SAP ERP 6.0Supplier Client:Employee (Professional User)Warehouse ClerkStrategic PlannerProduction PlannerProduction Planner (AUTO)Production Supervisor (AUTO)Shop Floor Specialist (AUTO)Supplier Process: Inputting Uneven Planned Independent RequirementSupplier Process: Running MRPSupplier Process: Checking Planning Situation in planning tableSupplier Process: Heijunka Leveling – Equally Distribution DispatchingSupplier Process: Heijunka Leveling –Setup time optimizationSupplier Process: Monitoring and Rescheduling Heijunka PlanningSupplier Process: Calling for Finished Products Using Kanban PullSupplier Process: Monitoring and Executing Heijunka SchedulingSupplier Process: Receiving Finished Goods into StockCompany Roles Involved in Process Flows:Key Process Flows Covered:
4 Scenario Overview – 3 Detailed Process Description: Lean Manufacturing - Heijunka LevelingUneven customer demands for several different products are levelled by a production planner to create an even production schedule (Heijunka schedule) for a finished goods production line. The production worker executes according to this schedule and calls consumed components within an upstream Kanban process. The shipping associate fills the shipping warehouse via Kanban calls from the finished goods production line.
5 Process Flow Diagram Lean Manufacturing - Heijunka Leveling Supplier Client / Plant 1000Uneven Planned Independent RequirementMRP RunCheck Planning Situation in Repetitive Planning TableHeijunka Leveling – Sub-daily SchedulingHeijunka Leveling –Setup Time OptimizationShipping Signal in KANBAN Board – Status EmptyCheck Assigned Planned Order in Heijunka LevelingPost Goods Receipt in KANBAN Board
6 Master Data Lean Manufacturing - Heijunka Leveling Supplier Client / Plant 1000A _SUPAir Conditioning Type AA _SUPAir Conditioning Type BA _SUPAir Conditioning Type CA _SUPAir Conditioning Type DA _SUPCoolant Unit Type AA _SUPCoolant Unit Type BA _SUPCoolant Unit Type CA _SUPCoolant Unit Type DA _SUPFan Unit All TypesA _SUPFan Unit All TypesA _SUPFan Unit All TypesA _SUPFan Unit All TypesFinished Product, Material Type = FERTSemi-finished Product, material type = HALBRaw Material, material type = ROH
7 Legend Symbol Description Usage Comments Symbol Description Band: Identifies a user role, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role.The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scenario.Role band contains tasks common to that role.External Events: Contains events that start or end the scenario, or influence the course of events in the scenario.Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scenario. Flow line (dashed): Line indicates flow to infrequently- used or conditional tasks in a scenario. Line can also lead to documents involved in the process flow.Connects two tasks in a scenario process or a non-step eventBusiness Activity / Event: Identifies an action that either leads into or out of the scenario, or an outside Process that happens during the scenarioDoes not correspond to a task step in the documentUnit Process: Identifies a task that is covered in a step-by-step manner in the scenarioCorresponds to a task step in the documentProcess Reference: If the scenario references another scenario in total, put the scenario number and name here.Sub-Process Reference: If the scenario references another scenario in part, put the scenario number, name, and the step numbers from that scenario hereProcess Decision: Identifies a decision / branching point, signifying a choice to be made by the end user. Lines represent different choices emerging from different parts of the diamond.Does not usually correspond to a task step in the document; Reflects a choice to be made after step executionSymbolDescriptionUsage CommentsTo next / From last Diagram: Leads to the next / previous page of the DiagramFlow chart continues on the next / previous pageHardcopy / Document: Identifies a printed document, report, or formDoes not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow linesFinancial Actuals: Indicates a financial posting documentBudget Planning: Indicates a budget planning documentManual Process: Covers a task that is manually doneDoes not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually performed, such as unloading a truck in the warehouse, which affects the process flow.Existing Version / Data: This block covers data that feeds in from an external processDoes not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; this step does not have any incoming flow linesSystem Pass / Fail Decision: This block covers an automatic decision made by the softwareDoes not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been executed.Diagram Connection<Function>Hardcopy / DocumentExternal to SAPFinancial ActualsBusiness Activity / EventBudget PlanningUnit ProcessManual ProcessProcess ReferenceExisting Version / DataSub-Process ReferenceSystem Pass/Fail DecisionProcess Decision