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Deploy New MMMM System

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Begin the physical deployment of the MMMM system. This will take time. Don’t underestimate the amount of work required to physically put in place the containers and racking for line, supermarket and stockroom areas!

Form Deployment Team

Assemble the team responsible for the physical setup of the Material Delivery system. The Line Design implementation team will be a part of this group, but anyone in the company can get involved. The key to a smooth setup process is advanced planning and preparation, so that each team member receives clear marching orders.

Train Deployment Team

Assess the team for any remaining training requirements that have not yet been covered. Provide the necessary training so everyone involved in the physical deployment understands not only the “What” but, most importantly the “why”.

Define/Document Policies and Procedures

Define and document any policies and procedures not yet in existence. A review of the Material Management Policies and Procedures by the entire team is presented here as an option, to make sure that everyone is one the same page.

Bins and Racks Available?

Assess availability of required supplies to deploy the MMMM system. Although most racking and bins are off-the-shelf items, there will be a supplier lead-time involved in bin and rack procurement, so allow enough time for this in the schedule.

Procure Bins and Racks

Acquire all necessary supplies to bridge the identified gaps. Some time may be needed to procure bins and racks, so allow for this time appropriately.

Bins Cards Printed?

Design and print all the labels/cards to identified the parts to be stored in all points of use and resupply. There are many ways to print labels from the Excel PFEP database. A necessary preliminary step will be to Sort, Set In Order and Shine the affected Kanban areas. Apply the 7S+2 methodology to accomplish this and promote sustainability of the changes.

Print Bin Cards and Labels

Design and print all the labels/cards to identified the parts to be stored in all points of use and resupply. There are many ways to print labels from the Excel PFEP database. A necessary preliminary step will be to Sort, Set In Order and Shine the affected Kanban areas. Apply the 7S+2 methodology to accomplish this and promote sustainability of the changes.

Sort and Distribute Cards

Organize the cards according to your deployment plans. Will you use teams by commodity, planner code, physical location, or process?. This is exclusively for you to define.

Set up Command Center

Establish a physical location on the floor, at the center of gravity of the material deployment, with all the necessary equipment to support the deployment.

3s Inventory Areas

Clean up the areas where the materials will be stored. Not much needs to be said here, other than this is an opportunity to make your mother proud.

Set up Rack and Storage Locations

Set up all the racks and other equipment for the MMMM system. Once the areas have been organized and cleaned, it will be possible to set up any new racking and storage locations. This work should be planned so as to not disrupt the normal workflow excessively.

Attach Labels to Bins | Fill Bins with KANBAN Quantity

Label and fill all bins. This may look like a “nothing task”, but it is very much a “something task”; just time yourself doing one bin and then multiply this time by the total number of parts to be handled. A big timesaver is to organize the effort to label and fill bins in a logical and efficient way. Sorting and distributing the printed labels will avoid confusion during this stage.

Conduct 100% Pull Sequence Audit

Audit the MMMM system with emphasis on the Material Flow chains (sequences). Once the Kanban system is set up, a full audit will be needed. Use the PFEP database as a checklist, and confirm the setup of every Kanban point and item.

Identify/Document Improvement Opportunities

Identify and document all Kaizen opportunities found during the deployment. These will range from better bins or labels to ergonomic considerations for material storage or retrieval.