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Advanced Material Management Workshop Syllabus

The 3-day workshop course syllabus covers implementing and managing a Kanban system for material control. Day 1 includes defining Kanban methods, planning Kanban cards for each part, and setting up physical workstations and supermarkets. Day 2 focuses on designing replenishment routes, measuring performance, and introducing level loading. Day 3 calculates total acquisition costs, audits the Kanban system, and discusses improvements and supply chain considerations. Participants engage in classroom lessons and team assignments to set up and exercise all aspects of the Kanban material control system.

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100 views2 pages

Advanced Material Management Workshop Syllabus

The 3-day workshop course syllabus covers implementing and managing a Kanban system for material control. Day 1 includes defining Kanban methods, planning Kanban cards for each part, and setting up physical workstations and supermarkets. Day 2 focuses on designing replenishment routes, measuring performance, and introducing level loading. Day 3 calculates total acquisition costs, audits the Kanban system, and discusses improvements and supply chain considerations. Participants engage in classroom lessons and team assignments to set up and exercise all aspects of the Kanban material control system.

Uploaded by

derdor
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Advanced Material Management Workshop Course Syllabus

Morning Day 1
Classroom: Introductions and Course Goals and Agenda. Classroom: Understanding the Current State: Review of the existing cell design, current volumes, current BOMs and parts lists. Use of MRP for material control. Classroom: Definition of Kanban and the five main Kanban methods: In Process Kanban, Two-Bin Kanban, Multi-Bin Kanban, Non-Repeating Kanban, Multi-Card Kanban. Team Assignment: A Plan for Every Part. Populate Kanban planning worksheet with base part number data. Spreadsheet and printers provided. Team Assignment: Kanban Sizing Calculations. Calculate target quantities for Supermarket and Line Materials.

Afternoon Day 1
Classroom: Complete a Plan for Every Part, including determining the correct Kanban method. Team Assignment: Finalize a Plan For Every Part. Determine Kanban methodology per part, container size, Kanban label design. Team Assignment: Set up physical workstations with labeled bins and correct quantities. Classroom: The supermarket strategy. Team Assignment: Set up Supermarket with labeled bins and correct quantities. Use Bosch-provided flow racks, bins and Orgatex products. Toyota Plant Tour: Tour workstation presentation and material supermarkets.

Morning Day 2
Classroom: Designing the replenishment route and calculating material handling resources. Team Assignment: Measure replenishment route distance, planned replenishment cycles, required resource calculations. Classroom: Measuring material delivery performance. Kanban performance metrics. Team Assignment: Set up Kanban Status Board. Classroom: Level-loading and the impact of variability on a Kanban system. Introduction to Heijunka. Toyota Plant Tour: Tour replenishment route process and use of AGVs.

Afternoon Day 2
Classroom: Train the Trainer. Conduct Material Handler training session. Team Assignment: Bring the cell live and exercise the material delivery system. Record replenishment route metrics. Conduct debrief and document proposed improvements. Classroom: Material information management with a Kanban system.

Morning Day 3
Classroom: Total Cost of Acquisition Analysis. Team Assignment: Calculation fleet design using analysis spreadsheet (provided). Classroom: Forklift and Fleet Management design. Guidelines for use of AGVs in the plant. Team Assignment: Calculate total cost of procurement for two items. Toyota Plant Tour: Tour warehousing and raw material storage. Outside supplier communication and Receiving Inspection. Team Assignment: Conduct audit of Kanban system, including a full pull sequence audit.

Afternoon Day 3
Classroom: Kaizen the Kanban system. Implementing a Lean Management System related to material management. Team Assignment: Improvements to Kanban system in the workshop. Classroom: Kanban and supply chain considerations. Use of MRP in a Kanban environment with suppliers. Team Assignment: Line Live. Bring the line live and conduct debrief meeting. Classroom: Conclusion and Final Remarks.

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