A Pull planning system halves lead time

Auxiliary company of the automotive sector defines a new value stream model by deploying production levelling mechanisms and using Kanban cards to streamline the information flow.

Reduction of lead time from 21 to 11 days

€2,5M reduction of stock

5% increase in productivity

65% reduction in storage area

Daily planning work delegated to middle management

NEEDS

To reduce stock levels.
To reduce logistic costs.
Greater flexibility (in terms of response to changes in demand).

IMPROVEMENT PROCESS

Analysing and designing a Lean value stream.
Designing a demand forecast model.
Production levelling.
Radical improvement of external logistics and integration with internal logistics.
Kanban for process interface connection.
Visualisation of the overall process.

Related methodologies

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Lean Manufacturing

Adjustment to demand using minimum resources and continuously eliminating waste.

Related methodologies

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Extended value stream

Integration of supply, distribution and manufacturing activities in an efficient overall value stream.