CASE STUDY

Inventory and system operation at international factories

Customer Overview

      Customers with 60 plants all over the world were using IFS at their bases in China and Thailand, but they had a problem if they could not operate properly after the introduction.

Task

  • Inventory is putting pressure on the management.
  • Inventory cannot be optimized using MRP.
  • Stocktaking is also a separate process at the base. It takes time but is not accurate.。
  • Use Excel because the system data cannot be trusted.

Proposal

      First of all, we started system operation work to understand the current situation. We investigated the entire system that operates in the background, Job, and the operation method of the user, and proposed the following actions.

・Phase 1

Educate how to use MRP, set production management KPI and follow up daily.

・Result

the customer’s production control department’s understanding of the system has greatly improved, and the production operation has changed from the system data.

・Point

It was likely that MRP obtains the correct results if there were supply and demand planning and inventory data, but it would be necessary to move inventory during quality confirmation or non-existent system inventory to locations that are not subject to MRP calculation. The point, This made it possible to see the correct system inventory quantity, trusted system data, and motivated users to utilize MRP.

This one successful experience motivates the next improvement and improves the efficiency of inventory.

・Phase 2

Perform inventory efficiently with barcodes

The challenge was clear. All inventory is done with paper and pencil.We do not know at all whether the inventory that takes place on the weekend for two days is over or not,Even after the stocktaking, it was necessary to stop the system for about two weeks and input the results. This kind of operation was a major cause of upset of the inventory system.

・Remedial measures

We purchased 80 barcodes handy and developed an application that connects to IFS from there. We introduced a system that reflects the system on the spot during inventory.

・Result

The aggregates, which used to take two weeks, can now be confirmed on the day they are counted, making the online real-time processing extremely efficient. Furthermore, the time that has been spent just for input until now has changed to time for checking differences, further improving the inventory system.

After performing these two phases, the factory turned into a positive spiral.

The system has become an indispensable, as it has become possible to trust the system data, see the data every day, and make job decisions, and to check the system history even when trouble occurs.

In the end, it had a positive effect on management. Inventory can now be properly controlled as desired, and it is now possible to maintain and operate it in appropriate situations.