to the SyteLEAN PullSystem

1

• Welcome,
• to the SyteLEAN PullSystem
• self-paced demonstration.

Improving business performance with technology.
2
Lean Manufacturing Concepts

• Lean Eliminate Wasteful Evils
• Over production
• Unnecessary processing
• Downstream resource waiting for late work
• Movement of goods or people without a purpose
• Correcting mistakes
• Time delays
• Starting work before necessary
• Shortages
• Pull vs. Push
• Push production or purchasing based on predicted
  demand.
• Pull production or purchasing based on actual
  demand or consumption (with buffers for
  variations).
• Best- Push system for seldom use or high
  variability items, Pull system for items
  normally carried in inventory.

3
What is the SyteLEAN PullSystem?

• The SyteLEAN PullSystem is a very simple and
  responsive inventory management system for items
  that are regularly purchased or manufactured.
• It is an electronic Kanban system that
  automatically and dynamically right sizes the
  selected inventory items based on average usage
  and variability in usage.
• It "pulls" the replacement orders when inventory
  is consumed, rather than pushing orders the way
  MRP does.
• It can be combined with MRP\APS to plan each
  inventory item using the most efficient method
  for each and the plans from both methods can be
  analyzed and executed in the SyteLine Planners
  Workbench.
• It can be used with SyteLine Forecasting to help
  you Right-size your inventory considering future
  demand.

4
How does SyteLEAN PullSystem work?

• When an item is issued to production or shipped,
  if the calculated trigger point is hit, it
  replenishes the inventory to the optimum level by
  creating Kanban planned orders that are
  combined with the APS\MRP planned orders, which
  can be reviewed and released in the SyteLine
  Planners Workbench.
• The right sizing calculations can consider both
  historical usage and forecasted usage and the
  look-ahead and look-behind periods can be
  user-defined.
• The net result is an inventory management system
  that automatically corrects itself for changes in
  demand and product mix and is much easier to
  deploy and manage than MRP.

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Best of MRP and Kanban

• Incorporates Strengths of MRP
• Considers future demand (firm and/or forecast)
• Lead time and days supply drive release
• Utilize Planner Workbench and Order Action Report
• Incorporates Strengths of Kanban
• Consumption will triggers replenishment
• Greater protection against forecast error
• Historical demand variability Right-Sizes
  inventory
• Simple to implement and manage

6
Pull Item Maintenance
Values Calculated by SyteLEAN

• An Order is triggered when Total Supply is below
  Trigger Point
• Replenishment amount to reach the Max Supply
• Not Ordered if not consumed no signal received

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Nightly Planning Produces Signals
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Acting on SyteLEAN Signals

• The suggestions of SyteLEAN are handled by
  SyteLine the same as suggestions created by
  MRP/APS.
• PLNs (action suggestions) are created when the
  trigger point is reached.
• PLNs are displayed on the Material Planning
  Workbench for review.

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Kanban Card JIT Pick List
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Supplier Forecast
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Identifying Best Items to Plan with Pull

• Simulator Analyzes item history/forecast to
  determine Pull candidates.
• Average Daily Usage (ADU) determined with
  Deviation from ADU.
• Items showing consistent ADU with acceptable
  deviation are identified.
• Simulator indicates quantities of materials in
  excess and their quantity and dollar amounts.

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SyteLEAN PullSystem Benefits

• Seamless integration
• With Syteline MRP, Item maintenance, Planning
  Details, Order Action Report, Planners
  workbench, etc.
• Responsive to both actual and expected
  consumption
• Increasing consumption will upsize inventory
• Declining consumption will downsize inventory
• Spikes in demand managed as exceptions
• Easy to implement
• Tools included to analyze and auto-setup Pull
  items
• Pull Logic is transparent to buyers/planners
• Defined Service Levels statistically maintained

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SyteLEAN Is it right for your operations?
For More Information or a complete product
demonstration please contact BTA [phone] Ra
ndy.Washam_at_BTAsystems.com Leigh.Lathrop_at_BTAsystem
s.com