There’s always that big debate of whether to use leg and detail and having one complex engineering master, or breaking it up into layers. From the recent projects I am working on, the latter is working out excellent.
Here’s how we use Easy lean to simplify our builds, simplify planning, and reduce inventory on the floor.
We had many complicated builds using a lot of leg/detail.
Here is an example of an engineering master that goes 6 fabricated layers deep comprising of 50 sub IDs (legs).
- Top layer – 1 final assembly
- 2nd layer – 5 sub IDs
- 3rd layer – 8 Sub IDs
- 4th layer – 10 Sub IDs
- 5th layer – 12 Sub IDs
- 6th layer – 14 Sub IDs
We broke out each of these Sub IDs as make-to-stock parts. As an order was created for the top level part, Easy Lean would go through the requirements and create firmed work orders with appropriate release dates for each. Release dates for each part is calculated by the parts “buffer”. The Buffer is basically the time it takes to complete that work order. In the example above, here are the buffers we assigned to each layer:
- Top layer – 1 final assembly – 4 day buffer
- 2nd layer – 5 fabricated parts – 5 day buffer
- 3rd layer – 8 fabricated parts – 3 day buffer
- 4th layer – 10 fabricated parts – 2 day buffer
- 5th layer – 12 fabricated parts – 3 day buffer
- 6th layer – 14 fabricated parts – 2 day buffer
When you calculate out the buffers and how the “layers” will be released it would look something like this:
Notice we only gave the shop floor what they needed. Instead of 50 work orders (sub IDs) getting printed and released all at once; the work orders were released in ‘layers’. No human intervention was required in the planning of things as Easy Lean planned it all. We could also set up replenishment levels and min/max/multiple rules in Part Maintenance for each make-to-stock part and plan all those to stock.
There are many other benefits of Easy Lean but what I find the most beneficial is this “MRP automation” it can do. As long as you can define the logic it needs to follow, Easy lean will do all the planning for you!
Jason Snoeyink is a frequent contributor to visualnuggets.com and is an active participant in the VISUAL community.
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