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Buffer Management The Control Mechanism for Synchronous Manufacturing  APICS-Twin City Chapter  Professional Development Meeting January 9, 2007 Rick Bernett  CFPIM, C.P.M.
[object Object],[object Object],[object Object],[object Object],[object Object],Agenda
According to APICS (Con’t) Both kanban, which is a part of the JIT philosophy, and drum-buffer-rope, which is a part of the theory of constraints (TOC) philosophy, represent synchronized production control approaches ,[object Object],[object Object],[object Object],Today, we will only focus on DBR
Drum Buffer Rope (DBR) ,[object Object],[object Object],Op. 4 is the constraint  Op.4 60/hr ,[object Object],[object Object],[object Object],Raw Materials Op.1 80/hr Op.2 90/hr Op.3 90/hr Op.5 90/hr Ship
What is the Drum? ,[object Object],[object Object],Drum Schedule Item  Qty.  Date A  20  2/15 G  45  2/17 K  75  2/20 Raw Materials Op.1 80/hr Ship Op.2 90/hr Op.3 90/hr Op.4 60/hr Op.5 90/hr What factors must be  considered when developing the Drum Schedule?   ,[object Object],[object Object]
What is a Buffer? ,[object Object],[object Object],[object Object],[object Object],[object Object]
Where to Buffer? ,[object Object],[object Object],[object Object],Buffer the Capacity Constraining Resource (CCR) Buffer Shipping Buffer Raw Materials RM 1 2 3 4 5 Ship RM 1 2 3 4 5 Ship
What is the Rope? ,[object Object],[object Object],[object Object],Drum Schedule Item  Qty.  Date A  20  2/15 G  45  2/17 K  75  2/20 Release Schedule Item  Qty.  Date A  20  2/10 G  45  2/12 K  75  2/15 Raw Materials Op.1 80/hr Ship Op.2 90/hr Op.3 90/hr Op.4 60/hr Op.5 90/hr Why is this important?
A More Complex Example ,[object Object],Ropes Ropes Z RM RM Ship RM RM Drum Constraint Buffer Shipping Buffer
What if there is no Active CCR? ,[object Object],[object Object],[object Object],RM Ship RM RM Ropes Drum RM No detailed schedule needed, but closely monitor CCR load Shipping Buffer
What is Buffer Management ? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],DBR Planning ,[object Object],[object Object],[object Object],[object Object],[object Object],Buffer Management Execute & Control ,[object Object],[object Object],[object Object],[object Object],[object Object]
What are we Buffering Against? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],MURPHY
Buffer Types ,[object Object],[object Object],[object Object],[object Object],60 minutes? ,[object Object],[object Object],How else can we buffer?
Time Buffer CCR ,[object Object],[object Object],[object Object],Bank of work (About 2 days worth) Work heading to the CCR ,[object Object],[object Object],RM Buffer 6 days
Time Buffer Mechanics ,[object Object],[object Object],[object Object],Constraint Buffer  Time   Shipping Buffer Time Ship CCR RM
Time Buffer (Con’t) Constraint Buffer  Shipping Buffer Ship CCR ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],RM
Time Buffer Details ,[object Object],[object Object],Order A takes 4 hours in the CCR. It needs to start on 1/15, first thing in the morning Order B takes 4 hrs. It needs to start on 1/15 at noon 1/21 pm 1/21 am 1/20 am 1/19 pm 1/19 am 1/18 am 1/17 pm 1/17 am 1/16 am 1/15 pm 1/15 am Due at CCR 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs Time in CCR  30 J 40 K 30 G 25 H 450 I 200 F 75 E 50 D 300 C 75 B 100 A Qty Order
Time Buffer Details (Con’t) ,[object Object],[object Object],A 100 4 hrs B 75 4 hrs C 300 8 hrs 1/20  1/19  1/18  1/17  1/16  1/15 8 hrs Buffer Status   as of 1/15 E 75 4 hrs D 50 4 hrs F 200 8 hrs H 25 4 hrs G 30 4 hrs I 450 8 hrs 1/21 pm 1/21 am 1/20 am 1/19 pm 1/19 am 1/18 am 1/17 pm 1/17 am 1/16 am 1/15 pm 1/15 am Due at CCR 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs Time in CCR  J K G H I F E D C B A
Details (Con’t) ,[object Object],[object Object],C 300 8 hrs 1/21  1/20  1/19  1/18  1/17  1/16  8 hrs Buffer Status   as of 1/16 E 75 4 hrs D 50 4 hrs F 200 8 hrs H 25 4 hrs G 30 4 hrs I 450 8 hrs J 30 4 hrs K 40 4 hrs 1/21 pm 1/21 am 1/20 am 1/19 pm 1/19 am 1/18 am 1/17 pm 1/17 am 1/16 am Due at CCR 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs 8 hrs 4 hrs 4 hrs 8 hrs Time in CCR  J K G H I F E D C
Using the Buffer Zones ,[object Object],[object Object],[object Object],[object Object],[object Object],Not expected to  be physically at the  CCR (or in Shipping) Fair chance to  be at the CCR  (or in Shipping) Expected to already be at the CCR (or in Shipping) Orders  missing in Red Zone-  Expedite Orders missing in Yellow Zone-  Monitor Orders missing in Green Zone-  Don’t worry!
Buffer Holes ,[object Object],[object Object],C 300 8 hrs 1/21  1/20  1/19  1/18  1/17  1/16  Buffer Status   as of 1/16 E 75 4 hrs D 50 4 hrs F 200 8 hrs H 25 4 hrs G 30 4 hrs I 450 8 hrs J 30 4 hrs K 40 4 hrs ,[object Object],[object Object],[object Object],K 40 4 hrs G 30 4 hrs E 75 4 hrs MURPHY
1. Prioritizes Work Raw Material Release ,[object Object],[object Object],[object Object],[object Object],CCR Orders  missing in Red Zone-  Expedite Yellow Zone Green Zone Red Zone Order missing in Green Zone- No worry! Order missing in Yellow Zone- Watch, learn! CCR  Buffer
Priority Rules ,[object Object],[object Object],RM RM Ship ,[object Object],Divergence Point Convergence Point CCR But how do we schedule operations between control points?
Buffer Consumption ,[object Object],Buffer Duration Buffer Duration – Remaining Duration Buffer Consumption ,[object Object],[object Object],[object Object],[object Object],[object Object],= While FIFO is the DBR default mode, here the buffer manager would re-prioritize the order Note – we would not likely expedite order A  9 9 – 3 Buffer Consumption A = = 9 6 = 66% 6 6 – 4 = 6 2 = 33% 12 12 – 3 = 12 9 = 75% Buffer Consumption B = Buffer Consumption C =
2. Signals if Buffer Size is Appropriate Green Zone 60% Yellow Zone 35% Red Zone <5% Probability of material in the Zone At Constraint Just Released Time ,[object Object],[object Object],[object Object],[object Object],[object Object]
3. Analysis of Red Zone Penetration ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Buffer Analysis Table
Buffer Analysis Graph
Buffer Management  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Real-time Priorities ,[object Object],[object Object],[object Object],Cycle consume & buffer zone colors help you focus on the problem: Is someone not following the priority? Operator Screen Operators’ priorities are always real-time Where do I go if I don’t have anything to work on?  Just retrieve priority lists for ALL w/c and go where you see Reds. It’s that simple! No start/finish dates for operation/work-orders Instills true relay-runner ethic
Pull-Based Replenishment  Easily identify stock out risks Monitor Inventory Position and Health Know when a part is starting to run low on Inventory Continuous Improvement   Goal is to Keep items in the “Yellow Zone”
Getting Started ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Questions? ? … (0)~ # ^ % $&#
Richard Bernett,  3sixty solution, llc  [email_address] 612-216-1629

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Apics Pdm Buffer Mgt. 1 09 07

  • 1. Buffer Management The Control Mechanism for Synchronous Manufacturing APICS-Twin City Chapter Professional Development Meeting January 9, 2007 Rick Bernett CFPIM, C.P.M.
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  • 31. Pull-Based Replenishment Easily identify stock out risks Monitor Inventory Position and Health Know when a part is starting to run low on Inventory Continuous Improvement Goal is to Keep items in the “Yellow Zone”
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  • 34. Questions? ? … (0)~ # ^ % $&#
  • 35. Richard Bernett, 3sixty solution, llc [email_address] 612-216-1629

Editor's Notes

  1. 24 Buffer Meetings held daily Short, to the point Status meeting only; Actions taken outside meeting Actions assigned to responsible team member Measure &amp; track penetrations greater than 1/2 the buffer Where Cause How often &amp; for how long Impact to the constraint Correct as needed Run Plant 030 Buffer Management &amp; discuss
  2. 24 Buffer Meetings held daily Short, to the point Status meeting only; Actions taken outside meeting Actions assigned to responsible team member Measure &amp; track penetrations greater than 1/2 the buffer Where Cause How often &amp; for how long Impact to the constraint Correct as needed Run Plant 030 Buffer Management &amp; discuss
  3. Illustrate a change in priorities, ease of automated expeditor