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LINKED Material Flow Program

STAGE 0: INTRODUCTION AND ORIENTATION
Introduction to the LINKED Program [LINKED]
3 Tasks
Introduction to the Lean Design Studio
How To Manage the Program [LINKED]
Download the Material Management Master Workbooks
STAGE 1: LOAD
1 Create Strategy & Master Plan [LINKED]
7 Tasks
1.1 Complete Material Flow Lessons [LINKED]
1.2 Develop Current State VSM [LINKED]
1.3 Start Continuous Improvement Database [LINKED]
1.4 Gather KPI And Establish North Star Goals [LINKED]
1.5 Create Material Management Dashboard [LINKED]
1.6 Form MMMM Design Team [LINKED]
1.7 Create Material Flow Master Plan [LINKED]
2 Set up PFEP Database [LINKED]
9 Tasks
2.1 Select PFEP Database [LINKED]
2.2 Train in Database Use [LINKED]
2.3 Electronic Data Available? [LINKED]
2.4 Populate Initial PFEP Data [LINKED]
2.5 Review Initial Data as a Team [LINKED]
2.6 Identify and Flag All Make Parts [LINKED]
2.7 Enter Test KANBAN Chain
2.8 Assign KANBAN Chain Code to Test Parts
2.9 Validate Sizing Calculations
3 Populate PFEP Database [LINKED]
10 Tasks
3.1 Document ABC Code Strategy [LINKED]
3.2 Document Commodity Codes [LINKED]
3.3 Define and Document Prep Codes [LINKED]
3.4 Define Standard Storage Bins [LINKED]
3.5 Define XYZ Strategy [LINKED]
3.6 Document Part Size and Weight [LINKED]
3.7 Identify ESD Requirements [LINKED]
3.8 Assign Storage Methods [LINKED]
3.9 Document Replenishment Signal Method [LINKED]
3.10 Document Receiving Method [LINKED]
STAGE 2: INVENTORY
4 Calculate Target Inventory Quantities [LINKED]
7 Tasks
4.1 Review and Finalize Usage Data [LINKED]
4.2 Establish Policy for Days On Hand [LINKED]
4.3 Create and Document All Material Flow Codes [LINKED]
4.4 Assign Material Flow Codes to Parts [LINKED]
4.5 Review Inventory Quantity Calculations [LINKED]
4.6 Perform Total Inventory Review [LINKED]
4.7 Adjust Inventory Calculations
5 Define Replenishment Signaling [LINKED]
13 Tasks
5.1 Flag Kanban Items in PFEP Database
5.2 Define Kanban Signaling Methods
5.3 Calculate Space Requirements
5.4 Establish Cut-Off Policy for Low-Usage Items
5.5 Identify and Tag Single Use Parts
5.6 Identify and Tag “A” Items
5.7 Identify and Tag “B” Items
5.8 Identify and Tag Quick Count Items
5.9 Identify and Tag Potential Kits
5.10 Complete Kit Delivery Planning
5.11 Identify and Document Items That Require Prep Codes
5.12 Identify and Document Any Special Handling Items
5.13 Identify Candidates for Vendor Managed Inventory
6 Design POU Material Presentation [LINKED]
12 Tasks
6.1 Define Design Principles
6.2 Create an Address System Including All Potential POUs
6.3 Conduct POU Gemba Walk
6.4 Flag Material Delivery Challenges
6.5 Review Kanban Strategy
6.6 Review Kitting Strategy
6.7 Document Seqencing Strategy
6.8 Document MRP Strategy
6.9 Document Subassembly Delivery Methods
6.10 Design Subassembly Presentation
6.11 Conduct Formal Material Flow Design Review
6.12 Create Training Materials
7 Define POU Storage Solutions [LINKED]
8 Tasks
7.1 Review Location Addressing System
7.2 Design the Materials Supermarket
7.3 Locate Supermarkets on the Factory Floor
7.4 Create Plan for Flow Racks
7.5 Create Plan for Custom Racks
7.6 Create Plan for Kit Racks
7.7 Calculate Staffing Requirements
7.8 Research Automated Systems
STAGE 3: NAVIGATE
8 Assign Conveyance [LINKED]
8 Tasks
8.1 Formalize Material Handler Team
8.2 Identify Hand-Cart Delivery Items
8.3 Identify Stock Chaser Delivery
8.4 Flag Fork Truck Delivery Items
8.5 Flag Tugger Delivery Items
8.6 Flag AGV Delivery Items
8.7 Flag Conveyor Delivery Items [LINKED]
8.8 Flag Items Requiring Custom Delivery Methods
9 Finalize Containerization Plan [LINKED]
8 Tasks
9.1 Document Current State Containerization Practice
9.2 Create List of Container Codes
9.3 Populate PFEP Database with Critical Dimensions
9.4 Calculate Optimum Container Size For Each Item
9.5 Team Review of Containerization
9.6 Train Outside Suppliers and Material Handlers
9.7 Rolll Out New Standards
9.8 Create Containerization Audit Process
10 Design Delivery Routes [LINKED]
14 Tasks
10.1 Acquire Factory Floor Layout In CAD
10.2 Identify All POUs on Layout
10.3 Design An Mark Aisles on Layout
10.4 Review Aisles for Potential Safety Issues
10.5 Map Addressing System on Layout
10.6 Set Delivery Frequency Policy
10.7 Identify Tugger Stops
10.8 Determine Coupled Versus Decoupled Strategy
10.9 Document Delivery Process with SWDs
10.10 Calculate Resources Based On SWDs
10.11 Create A Resource Calculation Spreadsheet
10.12 Design Delivery Routes Based on Standards
10.13 Train Material Handlers in Delivery Routes
10.14 Create Delivery Route Audit Forms
STAGE 4: KEEP
11 Train Staff on MMMM System [LINKED]
8 Tasks
11.1 Create Training Database
11.2 Create Certification Board
11.3 Populate Board and Create Training Plan
11.4 Create Training Materials
11.5 Assess Staff Training Needs
11.6 Identify Internal Trainers
11.7 Develop Training Plans
11.8 Deploy Staff Training [LINKED]
12 Deploy New Material Flow System [LINKED]
14 Tasks
12.1 Assemble Team for Physical Setup [LINKED]
12.2 Assess Remaining Training Needs [LINKED]
12.3 Create Remaining Policies and Procedures [LINKED]
12.4 Inventory Available Supplies [LINKED]
12.5 Acquire Necessary Supplies [LINKED]
12.6 Print All Labels and Cards [LINKED]
12.7 Organize Signs and Cards [LINKED]
12.8 Establish a Physical Location for Support Deployment [LINKED]
12.9 Clean Up Areas [LINKED]
12.10 Set Up Racks and Equipment [LINKED]
12.11 Label and Fill Bins [LINKED]
12.12 Physically Place All Bins [LINKED]
12.13 Conduct Full Pull Chain Audit
12.14 Identify All Kaizen Opportunities
13 Assess Inventory Record Accuracy [LINKED]
11 Tasks
13.1 Measure Baseline Inventory Record Accuracy [LINKED]
13.2 Train Staff in IRA [LINKED]
13.3 Set Tolerance Policy for ABC Items [LINKED]
13.4 Map All Inventory Transactions [LINKED]
13.5 Audit For Parts Outside of System [LINKED]
13.6 Create Scrap Procedure [LINKED]
13.7 Conduct Full Physical Inventory [LINKED]
13.8 Launch Cycle Counting Program [LINKED]
13.9 Create Pull Chain Audit Process [LINKED]
13.10 Investigate Root Causes of Inventory Errors [LINKED]
13.11 Strive to Reach Level V of Value Stream Maturity Model [LINKED]
14 Implement Sustainability Strategy [LINKED]
6 Tasks
14.1 Create List of KPIs [LINKED]
14.2 Define Visual Controls [LINKED]
14.3 Define Display Method for KPIs [LINKED]
14.4 Design Daily Accountability Meetings [LINKED]
14.5 Define Current State for Each Key Aspect [LINKED]
14.6 Develop and document Standard Work for Materials. [LINKED]
STAGE 5: EXTEND
15 Implement Supplier Pull [LINKED]
8 Tasks
15.1 Develop Supplier Onboarding Plan [LINKED]
15.2 Add Target Supplier to PFEP Database [LINKED]
15.3 Calculate Dollars Spent Per Vendor [LINKED]
15.4 Determine if Supplier is Capable [LINKED]
15.5 Calculate Potential Benefits [LINKED]
15.6 Begin Discussion with Target Supplier [LINKED]
15.7 Launch Pilot Supplier Program [LINKED]
15.8 Continue with Next Supplier [LINKED]
STAGE 6: DEVELOP
16 Kaizen the Material Flow System [LINKED]
7 Tasks
16.1 Train in Kaizen Process [LINKED]
16.2 Assign Leaders for Material Continuous Improvement [LINKED]
16.3 Identify Material Opportunities [LINKED]
16.4 Review Kaizen Database [LINKED]
16.5 Classify Improvement Ideas As Internal/External [LINKED]
16.6 Create Inventory Reduction Plan [LINKED]
16.7 Develop Kaizen Plan for Containerization [LINKED]
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Download the Material Management Master Workbooks

LINKED Material Flow Program Introduction to the LINKED Program [LINKED] Download the Material Management Master Workbooks
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Materials

There are two spreadsheet files that your team will be using to get started, and they can be downloaded by clicking on the Materials link on this page (above).

One of the first decisions that the LINKED team will need to make is where to store these spreadsheets so that all members and your Lean Design Studio mentors can get access to them. Here are some choices:

  1. Store the Excel files locally on a shared drive, and upload a copy on request.
  2. Convert the files to Google Sheets format and give team members access.
  3. Store the files in a OneDrive or Dropbox folder and give team members access.

Important! Feel free to modify the workbooks provided by adding and deleting columns as needed. The default workbooks are intended to be a starting point only, and they are not “cast in bronze”.

Download the Master Plan Workbook:  Linked Program Master Plan Workbook
Download the PFEP Workbook:              Linked Program PFEP Workbook

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