Supermarket

Lean fundamentals | Specify the Value | Type of Waste | Map the Value Stream | Value Stream | Establish the Flow | Implement Pull Work to Perfection | The Toyota House | Standard Work | Supermarket | 5 S | 5S examples | Lean Events | Glossary

- Why

Necessary to pull production
Provide visual management of inventory

- Design

Right-Size Bins
First-In-First-Out (FIFO) Important … Must be Poka-Yoked
Clear labeling drives visual management
Overflow Material and slow moving visible
Controlled Access
Transactional Rigor

Pull Production is a System of manufacturing in which a process withdraws (or Pulls) the parts it needs from the preceding process at exact timing intervals, in the exact standardized amount needed.

Supermarket that Supports a Line Producing to TAKT Time

Part arrangement in the supermarket should “mirror” the layout of the parts as used on the line
Racks need to be tipped toward water spider (picker) to ensure FIFO
Racks need to be labeled (front & back) with all pertinent info: part number, quantity, where used, picture, etc…
Height no taller than 6’ on either side of the supermarket rack
Create “specialty” aisle for components used on multiple lines
An empty bin is NOT a signal to replenish from the supermarket … an empty bin is a line item on the water spider’s shopping list
Only standard quantities of material can be taken from the supermarket to the line
Water spider emulates a supermarket “check-out” lane when systemic transaction is done to move material from Raw to WIP
Supermarket should be right-sized (through visual management tools) to identify abnormalities (too much or too little inventory)

Supermarket that Supports Order Specific Items (Accessories)

Part arrangement in the supermarket should be in alpha-numeric sequence for ease of picking & filling
Only items to ship-along with customer order should be on the pick-list

NOTE: Supermarkets should be dedicated for production only… Engineering, Service, etc should created purchase orders for their parts. Supermarkets should also be eliminated when flow is achieved.

What you Should Expect …

30% Reduction in mean pick time per order
45% Reduction in walking distance to pick
40% Reduction in on hand inventory
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