Lean production system

If you spend time in the Production, Warehouse, Purchasing, and Procurement units, you will frequently come across the following conversations. • We could not find the material; can we bring a new one right away?

• There is no material; clear the line as soon as possible, we are going to produce the other product!
• The semi-finished goods and materials inside the line are waiting because a part is missing.
• Production cannot keep up; our number of operators is insufficient.
• For reasons beyond our control we will not be able to make the shipment; it will be a little late, unfortunately.
• Those parts are sitting somewhere in the warehouse; please search and find them as soon as possible!
• We should assign other people as well to search for the material!
• There is too much work in the warehouse; our number of personnel is insufficient.
• Our warehouse space is insufficient; we are working with scarce resources.
• We skipped issuing the goods; the record stayed in inventory.
• These are the parts we searched for and could not find! When we changed its shelf, we forgot to make the address change in the system.
• This part was written on the delivery note; we did not look inside the boxes. The wrong material had come.
• We did not look inside the boxes; it was short.
• The other day they asked for it from production, saying it was urgent; we gave it, but we did not issue it.
• Every job is urgent; we cannot do them all today!

All of these problems come from certain recurring errors that arise in storage processes. Coming across these problems is inevitable, but what matters is how often they are experienced. In the table below, let us try to define the potential problems one by one and to set out their consequences.