Mike BrunsonFebruary 7, 2006

Lean Manufacturing Tour

2006 Santech Industries

Agenda

Product Flow

Material Management

Material Handling

Queue Establishment

Housekeeping

Reduction in Non-Value Added Activities

Old Warehouse Layouts

New Warehouse Layout

2006 Santech Industries

Previous Conditions

Overstock was Scattered

Conveyor was Isolated

Inventory and Pick Stations weren t Together

Auto Baggers were Central to O-Rings Only

Product Log Jams through Kitting

Current Condition

Overstock is stored Over Stock

OVERSTOCK

STOCK

Current Condition

Conveyor is Central to Inventory

STOCK

Current Condition

Pick Stations Located in Highest Volume Areas

STOCK

Current Condition

Auto Baggers Located at End of Conveyor

Conveyor

Auto Bagger

Current Condition

Product Flows through Kitting

Conveyor

Auto Bagger

Product Flow

Kitting

2006 Santech Industries

Previous Conditions

Monthly Inventory of Supply Items

Remote Locations were Used

Current Condition

Bagging Machines Bag Location

Order Point Level Reorder when Pulled

Reorder Queues Established

Bag Location and Control

Current Condition

Oil and Chemicals

Inventory Stored by Product Famlies

Oil and Chemical Storage

2006 Santech Industries

Previous Condition

Dependant on Fork Lifts

Heavy Parts Not Stored Safely

Current Condition

High Moving Items Stored in Reach of Ladder

Current Condition

Gold Zone

2006 Santech Industries

Previous Condition

Kits Piled Up at the End of the Line

Pickers Lost Time Looking for Kits

Current Condition

Beginning of the Kitting Process

Current Condition

The End of the Kitting Process

2006 Santech Industries

Previous Condition

Cluttered

Current Condition

Still Improving

Weekly 5S Audits

2006 Santech Industries

Current Condition

Less Travel

Easier Access

No More Supply Inventories

Several Process Improvements

Better Organization

Current Condition