Lean ERP Module

Lean manufacturing seeks to eliminate waste (non-value added activities) that inflate costs, lead times and inventory requirements. The Seradex ERP system does not, by itself, create a lean manufacturing environment. Many lean proponents argue that ERP systems actually hinder the adoption of lean manufacturing. These proponents are generally correct.

The vast majority of ERP systems on the market today do in fact incorporate waste and dictate processes that prevent adoption of changes prescribed by value stream mapping. Seradex was architect from the ground up to heavily support lean manufacturing. Seradex supports both traditional push (work order) and modern pull (agile, cell, flow, JIT, lean) manufacturing processes in an extremely flexible manner.

Some basic lean functionality includes:

Production is based solely on actual orders received (Seradex has no forecasting module)
Scheduling is based on daily production capacity and actual orders received
Goods can be produced in any sequence in batches as small as a single unit
Flexible backflushing capabilities
Production lines are balanced with synchronized takt and cycle times
Kanban is used to trigger material and component replenishment
Automated receiving to accounts payable processing
Support for make to ship production

However Seradex can offer much more to the company driving towards lean. Here are some of the lean benefits Seradex can offer the advanced lean practitioner:

Takt Time Calculator

Seradex automatically calculates Takt time synchronized to incoming orders. This works very well for companies with repetitive products that consume the same level of resources per unit. However fragmented markets, competition and sophisticated customers can require some companies to handle dizzying product variety-- often with lower volume. The Takt calculations don't work well when finished products can consume a wide range of material and labor resources. Here we must account for setup times, multiple routings and varied work times. Seradex overlays group technology and resource analysis to derive a workable takt time.

Heijunka Scheduling

Seradex demand leveling allows you to break incoming orders into scheduling weekly and daily takt time driven intervals. A heijunka schedule dictates the model mix scheduled on a given line. That schedule is executed on the floor through a signal. The signal can be shipping labels, paperless production display or cell schedule. If the takt time is altered the Heijunka Schedule can be easily readjusted. Once the schedule is updated the supplier daily schedules are automatically recalculated and forwarded to your suppliers.

Kanban Management

Kanban works extremely well for components under steady and relatively level demand. What about scenarios where demand for a successful product is increasing or sales are falling for an older product? What about the unusually large order or seasonal demand?

Seradex automates Kanban management. The system will indicate when additional Kanban cards must be issued, pulled or single card quantities adjusted. The system will also identify any spike demands from incoming orders that will exceed Kanban capabilities. The Kanban cards are all barcoded and a simple wand adds demand onto the daily supplier schedule.

Supply Chain Management

Seradex automatically issues daily supplier schedules by EDI, XML, email or fax. These schedules will include demand from both Kanban as well as buy to order items. These schedules ensure suppliers have visibility into your incoming orders so they can plan and achieve JIT deliveries. If your takt time changes the daily supplier schedules are automatically re calibrated.

Seradex also monitors supplier lead time and quality trends. Have all your major suppliers reducing their lead times compared to last year?

Bill of Material and Routing Management

Lean manufacturing will identify improvements through many activities including value stream mapping, kaizen events, set up reduction and cellularization. These activities will drive constant change to your bills of material and routings. Seradex ERP software enables you to make these changes rapidly. It is important that your product structures match the shop floor realities for Heijunka and supply chain synchronization. Seradex offers mass change and revision control so you have a full audit trail of all the changes.

Setup Time Trend Analysis

Get reports on total number of setups as well as setup times by cell by month. Monitor the impact of setup reduction programs.

What Seradex ERP Cannot Do for Lean

Software alone is not going make your plant lean. Seradex is one part of your management toolbox and can provide some support for your lean journey. But Lean transformation requires much more than great software. It requires significant cultural changes that include senior management commitment, extensive training, motivation, dedication, and perseverance. Factory and material flow redesign will require many changes on the shop floor. But if you are looking for software to help you and a software vendor that speaks lean please conta

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