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Design POU Material Presentation

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Establish the preferred material presentation strategy for each POU in collaboration with the Line Design team. Consider access and ergonomics for the Operator and the Materials Handler as key factors.

Define Material Flow Guidelines

Define and document the principles that guide the design of the Material Flow system. Review the Material Flow design principles with the design team, to ensure that all participants are on the same page regarding Material Flow goals.

Identify and List All POUs in the Line

Create a list of all of the Points of Use (POUs) that will need to be serviced through the material delivery system. Create an address system based on standard numbers or ID system for each station.

Review POUs With Line Design Team

Review the POU definition with the MMLD team to ensure all material presentation issues will be addressed. Do a physical walk-through with both the Material and Line Design teams, to validate your POU list and to understand clearly the delivery requirements and challenges.

Assess Material Fitment For All POUs

Flag any material delivery challenges that will need to be resolved regarding space availability and delivery access. This step can save having to re-do the delivery plan later on.

Assess Material KANBAN Strategy

Review the Kanban strategy with the Material Flow team, to ensure that all members are on the same page with the details of the methodology. You may need to work through and agree on methods and approach.

Assess Material Kitting Strategy

Review the Kitting strategy with the Material Flow team, to ensure that all members are on the same page with the details of the methodology. You may need to kit some items, due to space constraints, to reduce part selection errors, or to improve operator productivity (by reduce part selection time). Review the kitting strategy with the Material Flow team, and agree on a method.

Assess Material Sequencing Strategy

Review the Sequencing strategy with the Material Flow team, to ensure that all members are on the same page with the details of the methodology. You may need to sequence some items (deliver them one-by-one), usually due to space constraints. Review the proposed sequencing process with the Material Flow team, and agree on a method.

Assess MRP Controlled Material Strategy

Review the MRP strategy with the Material Flow team, to ensure that all members are on the same page with the details of the methodology. Some items may need to be controlled and delivered via the company’s MRP/ERP system. This is especially true for low-usage or custom items that are not consumed regularly. Map out and agree on the MRP integration strategy with the Material Flow team.

Review SUBs Presentation Strategy

Identify the method for presenting subassemblies to the main line. This may include building the subassemblies in an independent process and delivered to the line via Kanban or the subassembly may be built on a feeder line as a part of the flow process. Select the method based on the cost of the item, the floor space required, the material conveyance needs, and the risk of impacting down-stream production. Use a Decision Matrix to help decide, if appropriate.

Define IPKs Disconnect Process From Flow Line

Define subassembly presentation for feeder-built subs. If a feeder process is desired, work with the Line Design team to establish the signaling method and the optimum number of IPKs. Chances are excellent that it will be more than one IPK.

Train Staff on POU Design

Create the appropriate training materials, and train the relevant staff. There are many associates who will need to understand the Material Flow strategy, but who were not a part of the design team.