Just-in-time Maintenance Shop Supply Flow Kaizen Workshop
(5 days)

Overview | Description | Example Agenda | On-site Coaching Available

Overview top
Discover how to analyze your maintenance shop supply value stream, “see” its shortfalls, and apply lean principles and methods to significantly improve flow, decrease lead time, and reduce costs.

Description top

Just-in-time Maintenance Shop Supply Flow Kaizen Objectives:

  • Discuss just-in-time maintenance shop supply principles, value, and value streams
  • Through kaizen team interactions, create a comprehensive current state value stream map of the organization’s supplier-to-point of use maintenance parts shop supply value stream
  • Discuss key aspects of just-in-time maintenance shop supply operations, smoothed & balanced supply workload, visual process control, and kaizen principles & methodologies
  • Assist Kaizen team members in visualizing how JIT principles & practices can significantly improve shop supply processes, reliability, and parts & materials flow
  • Assist team members in visualizing, then designing an aggressive, yet feasible shop supply future state improvement design and an aggressive transformation plan
  • Discuss effective techniques to visually manage the maintenance shop supply process value stream and transform it to just-in-time principles and practices

To achieve these objectives, kaizen team members will:

  • Practice, through discussions and case study illustration, just-in-time maintenance shop supply value stream flow mapping, shop supply kaizen concepts, and team building
  • Develop current and future state maps of the shop supply value stream
  • Identify flow impediments which must be eliminated via process kaizen to achieve future state improvements and discuss mechanisms which support implementation

A maintenance activity’s shop supply value stream includes all actions to acquire parts & materials, stage them to effectively support maintenance actions, then provide them just-in-time to the value adding maintenance team accomplishing maintenance, repair, and overhaul activities.

Each action in this chain of activities is either value adding (e.g., being staged at POU) or non-value adding (e.g., being transported). "Seeing" your maintenance shop supply system from a value stream perspective means looking at the total system, not just a component  It means paying attention to improving the system as a whole, supplier to mechanic, rather than focusing on improving only an individual sub-processes.

By creating a current state map (where we
are now) you create a "visual" of maintenance shop supply process flow. From this baseline, you can apply lean principles to create an improved future state (where we want to be) vision of an ideal just-in-time shop supply value flow.

Just-in-time maintenance shop supply kaizen is a straightforward process. You map the process along a representative shop supply flow, design improvements through application of just-in-time principles, then document your improvement vision by drawing a future state map of the improved flow.

The results will be eye opening, revealing conditions and opportunities which might otherwise go unnoticed.


Example Agenda top

Day 1: Shop Supply Value Stream

Flow Kaizen Structure
Lean Enterprise Flow Fundamentals
Conventional Supply Principles
World Class Supply Chains
JIT Supply Chain Fundamentals
Value & Value Streams
Known Shop Supply Impediments
Value Stream Mapping Process
Receipt-to-POU Value Stream Mapping
Case Study Examples
  Move-All Forklifts
  Store-All Supply Warehousing
  Overhaul-All MRO Shop Supply
Supply Chain Value Stream Mapping
Team Current State  Assessment
1st Day Progress Wrap-Up

Day 2: Current State Supply Value Stream Mapping

Team Receipt-to-POU Current State Process Assessment
Team Receipt-to-POU Current State Map Development
Team Receipt-to-POU Current State Map Presentations
Group Current State Map Opportunities
Just-in-time Maintenance Shop Supply Principles & Methods
  - Creating Value Stream Flow
2nd Day Progress Wrap-Up

Day 3: Just-in-time Shop Supply

Just-in-time Maintenance Shop Supply Principles & Methods
  - Orchestrating Flow
  - Smoothing Requirements
  - Visual Supply Control
  - Work Cell Layout & Flow
  - JIT Pull Processes
  - JIT Supply Chain Flow
  - JIT Transportation
  - JIT Inbound Supply
  - Cross-Docks Operations
  - JIT Distribution Centers
  - JIT Processing Centers (JPC)
Just-in-time Materials Flow
  - JIT Receiving & Putaway
  - JIT Internal Materials Flow
  - JIT Storage
  - JIT Order Picking
Improving Flow thru JIT
   - Integrating PRP into JIT
   - Improving Resource Information
1st Shift - JIT WIP Flow Demonstration
3rd Day Progress Wrap-Up

Day 4: Inventing a Better Future State Flow

2nd Shift - JIT WIP Flow Demonstration
Receipt-to-POU Future State Mapping
Future State Case Studies
  Move-All Forklift
  Store-All Supply
  Overhaul-All MRO
Team Receipt-to-POU Future State Process Improvement Assessment
Team Receipt-to-POU Future State Mapping
4th Day Progress Wrap-Up

Day 5: Becoming Lean

Team Receipt-to-POU Future State Map Presentations
Group Receipt-to-POU Future State Opportunities Discussions
Group JIT Future State Shop Supply Impediments
Supply Chain Future State Mapping
Future State Performance Metric Discussions
Becoming Lean
JIT Supply Chain Future State Transformation Planning
Wrap-Up & Workshop's Value

On-site Coaching Available top
To request this on-site Just-in-time Maintenance Shop Supply Flow Kaizen Workshop, please contact Jim Price at (502) 570-2766 or (859) 351-3215 (mobile) or via email: .