POWERTRAIN GROUP. Continuous Improvement Meeting April 23-24, 2007 – Litchfield, MI Metaldyne Korea. Safety Performance. Lean Assessment. [Note: double-click on this chart to open data entry window; enter current and February 2006 summary data from Lean Assessment file]. Define the Problem
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Continuous Improvement Meeting
April 23-24, 2007 – Litchfield, MI
Finding Root Cause of Overstock
Team Training/ Seminar, Visual Factory, etc
“Inventory Status” & “Shipping Plan Sheet”
ControlLean Assessment Discussion-Reduce inventory
1. Define (Problem)
1) MKL had too much stock.
(President’s Request: 25% Reduction)
2) MKL Procurement & Logistics Team lacked of Knowledge/ Skill for Inventory Control.
C GroupLean Assessment Discussion-Reduce inventory
1) Team achieved Scientific Management Skill
through Education/ Training and Team Seminar.
-. ABC (or PQ) Analysis
-. Ordering System
Fixed-Period Sys, Fixed-Q’ty Sys, Two-Bin Sys,
Safety Stock, etc.
-. Visual Factory
2) Apply the Knowledge to Reality.
-. ABC Analysis (by Jeremy)
A Group: Components from US Supplier
-. Ordering System
A Group: Fixed-Period, B Group: Fixed-Q’ty, C Group: Two-Bin
-. Visual Factory (by YongBae Lee)
1) Inventory Turn: From 9.2 Turns to 17.9 Turns
(World Class: Over 10 Turns Ex: GM 10 Turns)
Target for 2006 is Over 15 turns. (10 turns Inc. parts on the ship)
2) Reduction Amount
708 MKW with Qt’y of 21,186 BSMs in Jan. 2006
; means 1,001MKW with Qt’y of 30,000 BSMs.
; amount to saving 4,167,000 KW per month (if 5% Bank interest is considered)