At the end of so loading, the loading handle should be placed at the unloading position. Ftbrands helped Yuken India streamline its Kanban system
softbrands' supply chain relationship management (SCM) software demanstream solution played a key role in the transformation of enterprises to lean, helping enterprises achieve the maximum benefits. Demandstream not only helps the company automate its supply chain, but also successfully integrates the existing enterprise resource planning (ERP) management software of Yuken India Company with the Kanban system seamlessly
yuken India pipelined its Kanban system 1/13/2004 (from) abhinavsingh said, "SoftBrands' demandstream lean production solution has helped Yuken India pipelined its entire Kanban system, which makes the company profitable."
for medium-sized enterprises such as Yuken India, it is definitely not a simple thing to implement the Kanban system developed according to just in time production (JIT). However, their hard work has been rewarded. The successful implementation of the system has significantly improved their work efficiency and production capacity. The revenue of Yuken India, which once fell, began to rise rapidly, and everything was developing in a direction conducive to the company. The company introduced the Kanban system in 2002, which began to transform the enterprise to lean. SoftBrands' supply chain relationship management (SCM) software demanstream solution plays a key role in the transformation of enterprises to lean, helping enterprises to maximize benefits. Demandstream not only helps the company automate its supply chain, but also successfully integrates the existing enterprise resource planning (ERP) management software of Yuken India Company with the Kanban system seamlessly. It should be the first case in the same industry that demandstream is fully integrated with the existing customized ERP system of the enterprise and has achieved successYuken was first established in India in 1976. Now it has established economic and technical cooperation with yukenkogyo company in Japan. From 2002 to 2003, the annual output value of the company was 400million rupees. The company produces water conservancy equipment, such as industrial water pumps, mobile application equipment, water pressure valves, mobile valves, and complete water conservancy systems to meet specific consumer needs. The company has 220 employees in India, and has offices all over India, with 44 dealers in 31 cities across the country
lean production and Kanban system
the introduction of Kanban system is part of the company's technological restructuring. From 1998 to 2000, the company's revenue showed a sharp decline. At the end of fiscal year 1999, the company's revenue fell from 290 million rupees in fiscal year 1997 to 240 million rupees. The existence of a large number of unused inventory of finished products is one of the main reasons for the company's low profitability. Therefore, the company decided to introduce lean production to solve this problem in 2000. In order to transform to lean production, the company also introduced the Kanban system using the concept of just in time production (JIT). Lean production mode straightens out the production process and brings hope to the company. This project includes, first of all, clarifying the product value from the consumer's point of view, determining the value stream (determining the sequence of processes from raw materials to final consumers), making a value flow chart, and using a pull management system (avoiding excessive production) to try to achieve an ideal level.. The goal of the project is to meet the consumer's need for what product and when he needs it at the most reasonable price and the least cost
inventory is a part of Kanban system. Using Kanban can make the lean production mode run more effectively in a pull environment. There are three main inventory management systems included in this Kanban system. The inventory management system includes three aspects: CONWIP, double box system and fixed time and variable quantity system. In CONWIP system (continuous work in process) pallet is used as kanban. Each pallet containing spare parts for production has a unique label, and it can be identified by its thin bar code label and part pictures. When the pallet is ready to move to the next operation station, a form containing all pallet tag numbers is used to identify the pallet to be moved. By scanning the pallet tag number barcode, the system can identify the production materials required for the current and next operation stations. In the double box system, two boxes containing parts for production are placed up and down in the production area. Once necessary, the system will extract the materials required for production from the upper inventory box. When the upper inventory box is empty, the strip coded plastic slot of the lower inventory box will be removed, and the positions of the two inventory divisions will be changed to put the empty inventory divisions below. After the barcode removed label is scanned, two vouchers will be generated immediately: one is the notification voucher of the scheduling supplier, and the other is pasted on the plastic slot and put it into the empty inventory cell. The supplier in turn pastes the dispatch summons and dispatch card together. By scanning the bar code during the operation of the mortar tensile testing machine, the system can check the inventory parts and generate the required material list. Results the materials received by the dual inventory grid system will be put into the inventory grid below, and the labels will be placed back on the plastic trough
fixed time variable quantity system (ftvq) is used for components with long lead time, such as imported parts. You should receive the inventory of parts every month and fill in the record card. Since it may take 3-4 months to replenish imported parts, the order will be placed one month before the parts are consumed
the inventory cost of Yuken India in 2000 was about rs. 22million. As both lean production and Kanban system focus on the inventory of finished products, the inventory cost has been reduced to 3million rupees. The revenue of Yuken India also increased from 280million rupees in 2000 to 400million rupees in 2003
streamline the system
the company has felt the need to combine lean production with Kanban system and the company's customized enterprise resource planning (ERP) solutions. Although ERP system still plays a role in management, it also has some limitations. Narayanrao, vice president and operating officer of Yuken India, believes that "when you manage 3-4000 components through this system, there is always the possibility of demand fluctuations. Therefore, demand fluctuations cannot smoothly deal with non-stationary growth within a certain range."
the company also observed that due to the fixed size of boxes and pallets in the double box system and CONWIP, they cannot cope with demand fluctuations and continue to drive their growth. Manually resizing boxes and trays is cumbersome, complex, time-consuming, and error prone. More directly, demand fluctuations may just affect overall production capacity
demandstream solution enters the company's vision
yuken India needs a system to effectively improve its lean production and Kanban system performance and overcome its limitations. Rao, head of Yuken India, believes that, "It is one of the most challenging problems to have a system that can make our existing internal enterprise resource planning (ERP) system into a whole and customize it according to the production environment. Demandst drafted the standards of electronic compression tester (q/0105drk002 (2) 013), electronic compression tester (q/0105drk001 (2) 013) and electronic tensile tester (q/0105drk003 (2) 013) After these three enterprise standards ream, we can successfully achieve this goal. " However, it is not easy to make demandstream and the internal enterprise resource planning (ERP) system of the company as a whole and customize users according to the requirements of Yuken India. This requires a very comprehensive understanding of the production environment and personalized user customization of the solution. A special team from SoftBrands and the project team of Yuken India worked closely together to complete the integration of the system and personalized user customization. Johnjagadeshj, deputy general manager of information technology (it) and Materials Department of Yuken India, believes that "the reason why we finally chose demandstream solution is that it has the characteristics of versatility, openness, integration, convenient use, support for multiple languages and products, and has the ability to successfully support our pull system."
the implementation of demandstream began in June 2003 and was completed at the end of August 2003. The whole project covers a wide range of areas. The project team is composed of seven members, four of whom are from Yuken India and the other three are experts from SoftBrands. They worked out a comprehensive work plan and demonstrated the integration of demandstream and customized ERP system. The SoftBrands team developed an interface between customized enterprise resource planning (ERP) and demandstream solutions by studying existing systems
softbrands team then conducted a conference room trial run experiment. The team includes four members from the inventory, shopping malls and production departments of Yuken India. They have established a simulation environment in the conference room, which helps SoftBrands demonstrate their demandstream solution capabilities in a timely manner. In addition, the SoftBrands team also undertook a two-day training course to train the staff of Yuken companyBinumathews, director of SAARC of SoftBrands, said, "two other experts from SoftBrands' U.S. headquarters also play an important role in this project. It is the first time for us that demandstream solution can seamlessly integrate with customized ERP products. Demandstream can integrate with various standardized ERP systems, which has been achieved worldwide."
advantages of demandstream solution
demandstream solution significantly reduces the inventory level. Because it has the functions of supply chain operation and workshop job management, it realizes the smooth operation of enterprise operation. Since demandstream has the ability to dynamically respond to any shortage of parts (i.e. replenish immediately in case of lack), it can achieve zero inventory. The system has the ability to integrate data between various departments of Yuken company and the existing ERP system. The implementation of demandstream also strengthens the original Kanban system. Rao, the head of Yuken company, explained, "demandstream has reset the size of boxes and pallets in CONWIP system and double box system, and adopted dynamic Kanban, which can be allocated according to the daily needs of parts and components in the enterprise production, and solved the problem of the original kanban. It has successfully controlled the inventory. Demandstream also helped us improve our ability to pull the system and make the enterprise production and operation management more smooth."
demandstream makes the production run more stable and smooth. The inventory level is significantly reduced. Because it adopts the functions of supply chain operation and workshop operation management, it realizes the smooth flow of enterprise operation management. The system has the ability to successfully integrate data between different departments of Yuken company and the existing enterprise resource planning (ERP) system, and realizes dynamic Kanban management
demandstream effectively recalculates the size of boxes and pallets in CONWIP system and double box system, and reconfigures the number of prepared parts according to daily needs. Inventory is well controlled. Demandstream solution also helps
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