Mixed Model Material Management Online Course

Shortage-proof your material delivery systems,
without overstaffing or wasting resources.

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Advantages of Mixed Model Material Management

Mixed Model Material Management is a step-by-step methodology for designing a Lean material flow system. This course was designed with manufacturing in mind; however, we have also successfully applied the same methodology in several healthcare environments. It starts with the creation of a comprehensive database of part-related information, called a Plan For Every Part. It also requires a deep understanding of the methods of Pull , Flow and Kanban.

The result is a material delivery system that supports the management of a large number of different products, options, and items, with high efficiency and quality. We would go so far as to claim that your material delivery system, following this methodology, would essentially shortage-proof your production lines.

The tools of Mixed Model Material Management can handle inevitable changes in mix and volume, without delaying or stopping the line. And it can do so efficiently, without overstaffing or wasteful material delivery activity.

This is how the “big boys” design their material management systems. This methodology is being used by manufacturing leaders like Toyota, John Deere, Ingersoll Rand, The Boeing Group, and many others. It has also been used in healthcare facilities including Maine Health, Orange Regional Medical Center, and White Plains Hospital in New York. You can learn it too.

John Deere
Maine Health
Orange Regional
Cummins

A Word from Our Participants

"Excellent! This is an excellent class that needs cross-functioned group participation (Operations, ME, Material Flow, Supply Management, Supervisors)."

— Wade, John Deere

"The course was very well prepared in terms of content, timing, examples, and practical applications. It is a great source to provide value to our organization."

— Sharleen, Ingersoll Rand

"I really found the course relevant to the work I do for my company. Very impressed with the course."

— Chad, Boeing

Benefits

Shortage-proof your lines.

Shortage-proof your lines.

Optimize material storage space.

Optimize material storage space.

Improve operator productivity.

Improve operator productivity.

Improve inventory turnover.

Increase inventory turnover.

Flexibility to respond to changes in the market.

Flexibility to respond to changes in the market.

Standardize material containers and quantities.

Standardize material containers and quantities.

Developing This Course

Our Story

We have been teaching live workshops on Mixed Model Material Management and Kanban since 1994, and the best practices related to this subject have advanced quite a bit since then. Thousands of companies around the world are using this approach to high-mix manufacturing, and many have adopted it as their corporate standard across all factories. The optimum management of materials is not a minor detail. It is central to a successful Lean Mixed Model strategy, and a requirement for any manufacturing company.

Now that the technology to deliver online training is maturing, new elearning software and high internet speeds have made delivery of high-quality training courses possible, with the quality that we want.

The development of our public online Mixed Model courses was both helped and delayed by a request from one of our largest clients, a Fortune 100 manufacturing company with plants all over the world.

"Create," they said, "both live and online versions of your Mixed Model Material Management course, customized for our company. Use company-specific examples and photos, make sure that corporate policies and procedures are adhered to, and make it available in seven different languages, for world-wide deployment."

The creation of the public and general online Mixed Model Material Management course was to follow, after several years of development. It is now available!

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What is Included?

We've broken the Mixed Model Material Management curriculum into short, manageable lessons available 24/7. Lessons are complete with real-world examples and quizzes to drive home comprehension.

17
Lessons

8
hours of instruction

17
Quizzes

12
Audits

Mixed Model Material Management Roadmap

Mixed Model Material Management Roadmap

Leonardo Group Americas has developed a Roadmap for Mixed Model Material Management as a way to provide all companies with a standard method to design and create high-performing material delivery systems. The reasons to have a roadmap are many but it all boils down to knowing where you are heading when you start a material management project. To keep traveling in the right direction you need to have a roadmap.

A roadmap is a form of Standard Work for material delivery design. This will give you the ability to improve your approach over time, moving towards perfection. It gives you a Standard to measure from. As Taiichi Ohno said: “Without Standardization there can be no improvement”.

If you are a potential member of a Material Flow team, think of the roadmap as your checklist for Mixed Model Material Management. That's one less thing to worry about!

Principles of Mixed Model Material Management

Principles of Mixed Model Material Management

If you think that line design is something that matters to somebody else, you may want to reconsider that position. Understanding the benefits of a Mixed Model Flow Line will enable you to plan with far better accuracy, and communicate these benefits to others.

How do you know if the line is performing as expected? Is that slow down normal? Getting educated in Mixed Model line design will enable you to “read” the line so you know how it is performing.

History of Mixed Model Material Management

History of Mixed Model Material Management

One of the first applications for Lean methods was in the area of Material Management, dating back to the 1950's. In this lesson we've introduce you to the surprising origens of the Kanban system, and how these methods have continued to evolve over time.

Familiarity with the evolution of Lean Material Management will enable you to better understand the logic and rationale of these powerful methods.

Plan For Every Part (PFEP)

Plan For Every Part (PFEP)

The starting point for the creation of a Lean Material Management system is the creation of a Plan For Every Part database. This is a repository of part-related information, for every item that will need to be procured or produced.

While traditional ERP/MRP systems contain many of the data elements that will be needed in the Plan For Every Part, this information is usually scattered across many different modules and database tables. This makes it hard to see everything related to a single item in one place. In this lesson you will learn how to create a PFEP system, and why it is so important.

Kanban Basics

Kanban Basics

The Japanese word Kanban translates as "signal", and can take many forms. In this lesson we'll review the mechanics of the basic Kanban method, as it applies to the control of material flow. In later lessons we'll review the various types of Kanban signals, and how to calculate Kanban inventory quantities.

Kanban Signals

Kanban Signals

Since the term Kanban means "signal", this lesson focuses on the various types of signals that might be used in a Kanban system. These signals are largely manual, and so it is important that they be clear and unambiguous. Otherwise the material system may not know that replenishment is needed.

Additional Signals

Additional Signals

In this lesson we'll cover some of additional material replenishment techniques that you will need to know about, and apply appropriately. Included in this lesson are methods like MRP-generated signals, and Supplier Managed Inventory.

Planned Material Quantities

Planned Material Quantities

The Kanban method relies on standard quantities: when material is replenished, it is in the same quantity. In this lesson you'll learn the Kanban Sizing formula, as it applies to Point of Use materials as well as material quantities in the Kanban Supermarkets and warehouse.

Workstation Design

Workstation Design

Presentation of materials at the various Points of Use is a critically important element of a Lean Material Management system. In this lesson you'll review the standard goals of optimum workstation material design, as well as take a look at ways to solve challenges related to large parts and high part mix.

Storage Solutions

Storage Solutions

In the lesson on Workstation Design we focused on material presentation at the Points of Use. In this lesson we'll expand that subject, by examining storage solutions and best practices in the Kanban Supermarket and warehouse areas.

Overcoming Changeovers

Overcoming Changeovers

Changeovers provide a special challenge to both Line Design and Material Management. Nothing is being produced when a machine is being changed over, so that downtime will need to be overcome with inventory. In this lesson you'll learn how to overcome changeover time through the use of a Kanban Supermarket and optimized batch (Kanban) quantities.

Material Conveyance

Material Conveyance

Materials will need to be delivered, and there are a host of ways to accomplish that. We'll be looking at the five most common methods, from hand carrying to Automated Guided Vehicles, and help you determine the best method. The conveyance method also is documented in your Plan For Every Part.

Designing Delivery Routes

Designing Delivery Routes

When it comes to material delivery, think "streetcar" instead of "taxi cab". A street car runs on a designed and predicable route, and runs to a fixed schedule. In this lesson you'll learn how to design a formal delivery route, based on standard tasks and times. You'll also need to decide if you will use a "coupled" or "decoupled" delivery route system.

Containerization

Containerization

The types of containers that will be used in your facility need to be standardized, limited, and for the most part small. Determining the correct container size for each item to be managed is a part of your Plan For Every Part database, and in this lesson we'll cover how to set proper container sizes and how to deal with exceptions.

Design Principles

Design Principles

Your Material Management team needs to be doing their design work, as well as running the material delivery system, based on a set of best practices. In this lesson we'll review the 10 main Material Management principles that will need to be observed and accomplished.

Inventory Record Accuracy

Inventory Record Accuracy

Lean Material Management still relys on the use of computer systems for a variety of purposes, including long-term planning, communicating with outside suppliers, controlling low-volume items, and financial reporting. Inaccurate inventory records will drive a host of ills, including bad material planning, incorrect balance sheet numbers, part shortages, and lack of trust in the formal system. This lessons covers the way to fix and sustain high Inventory Record Accuracy.

Material Flow Leadership

Material Flow Leadership

One of the key aspects of a Lean Material Management system is the ability to both sustain it, and continually improve it. This is called a "Lean Management System", and this lesson addresses the main elements that need to be addressed from a management perspective.

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Certifying Body

The Lean Design Institute is an international collaboration of leading Lean Process Improvement experts.
Our headquarters are located in Boulder, Colorado, USA.

Lean Factory Group

Lean Factory Group

Members include SAP, Orgatex, Leonardo Group GmbH, Syskomp, L-Mobile, Werma, 4D Flexiplat
Leonardo Group Americas

Leonardo Group Americas

Boulder, Colorado
Leonardo Group GmbH

Leonardo Group GmbH

Munich, Germany with offices in Switzerland, USA, Hungary, Romania, China, and Vietnam.
Kaizen Kulture

Kaizen Kulture

Manchester, United Kingdom
HLT Network

HLT Network

Buenos Aires, Argentina with offices in Montevideo, Uruguay
Phase2 Partners

Phase2 Partners

Denver, Colorado
MBizM

MBizM

Kuala Lampur, Malaysia with offices in Penang
Pisa Consulting

Pisa Consulting

Western Cape, South Africa