Lean Execution Suite: In the shift to a global, customer-centered economy, manufacturers must be more responsive in order to thrive. How quickly and efficiently can you change your processes to meet changing demands? Ultriva is leading the way toward more efficient lean business practices with a practical, automated approach. We are focused on helping businesses to improve collaboration and drive streamlined processes through demand and supply—removing the traditional tiers that can slow down your operations. We do it with an execution platform that facilitates the flow of information and materials across boundaries to give you complete visibility while making better use of your time and resources. Our modular, web-based tools are designed to complement and extend the value of the businesses systems you already have in place, such as MRP and/or ERP. Deploy them quickly in your high-impact areas—whether in finished goods, raw materials replenishment, or production management, and get an immediate improvement across the board. Electronic Kanban Overview: Ultriva Electronic Kanban™ software automates and enhances the manual Kanban manufacturing approach pioneered by Toyota. Ultriva Electronic Kanban aligns inventory levels with actual consumption by triggering signal to the supplier or producing location or stock area to deliver a new “lot” of material whenever a Kanban card is consumed. Ultriva provides a close loop Kanban by keeping track of who did what, when and where there by generating continuous improvement metrics. The Kanban card flows through different states based on the actions performed. Unless the previous step is completed the material cannot move to next state. Each Kanban card throughout the replenishment cycle is tracked in real-time, providing tremendous visibility while ensuring that stock-outs are avoided, re-order sig
Ultriva Lean Execution platform consists of Collaborative Electronic Kanban (CEK), Lean production and OEE modules. CEK, which is the flagship product of Ultriva, automates and enhances manual kanban manufacturing approach pioneered by Toyota. The Collaborative Electronic Kanban supports several modules to manage raw material, work-in-process and finished goods replenishment. All the modules that run on Lean Execution Platform are described below:
Supplier Kanban module deals with replenishment of raw materials between the plant and external suppliers. Kanban loops are established between consuming (or picking) locations at the plant and suppliers.
- The module allows planners and buyers to set kanban sizing for the parts, visually monitor the ordering process, react to exception alerts and obtain metrics for continuous improvement.
- The module allows the suppliers to accept the kanban orders, process them with in their lead time, ship them with Kanban labels and monitor their delivery performance.
The module is collaborative in nature thereby engaging the buyers and suppliers to work towards a single goal - Have the right parts at the right time at the right place. Everyone needs only a browser to access the application and hence makes it easy for the plants to manage their gloabal supply chain.
The Kanban signals can be triggered by scanning the kanban label at the point of use. Alternatively plants have an option of doing virtual kanban using on-hand inventory data from their ERP system.
Schedule Based Replenishment (SBR)
SBR addresses the critical need for companies to manage Kanban and traditional forecast based material replenishment within a single application environment. Companies which have long lead time parts and inconsistent demand patterns now have a collaborative lean system to accomplish their goals of continuous improvement.
Ultriva Schedule-Based Replenishment provides buyers and suppliers with a single, integrated replenishment interface that shows the status for every order in the system – both kanban and non-kanban.
The SBR system:
• Systematically publishes forecast, planned orders and change orders based on demand changes.
• Automates and streamlines ordering processes.
• Provides suppliers an environment to accept, make changes and collaborate in the purchase order execution.
• Tracks orders with suppliers while they are in process and in transit.
• Provides suppliers with standardized shipping labels with barcodes, eliminating data entry during receiving.
• Consistently monitors supplier performance.
SBR gives suppliers real-time visibility into forecasts and the ability to improve performance by responding to active orders faster. When active orders are received, suppliers can accept the order and the requested delivery date, suggest an alternative delivery date, or propose a delivery schedule with multiple shipments.
The internal Kanban module allows the users to set up multiple work centers and associate consuming work centers with the supplying work centers. Work Centers by definition is a virtual work area which could be consuming location (like a Final Assembly) and/or a producing location (like a Sub Assembly) and/or a storage location (like a Supermarket). Any number of work centers can be created depending on how many areas need to be tracked. Once the work centers are created then depending on the material flow, the consuming work center is mapped with the producing WC and/or Storage WC. Like supplier Kanban, during this mapping process, lead time, transit time (if any), lot size etc. can be defined. All the reports and continuous metrics will be provided for the internal Kanban as well.
This module is an add-on to internal Kanban module. As the Kanban signals are received at the producing WC this module allows the same to be sequenced for production by the operator. The sequence of production can be customized based on several factors depending on the plant’s business process. It could be as simple as FIFO or can be as complex as sequencing on several parameters like, family, boring size, color or other product spec. The supervisor can define these specs at WC level. In addition, supervisor can set up work center operational hours, schedule offset, set up time and cycle time for production.
This module provides visual cue to what is being produced at each work center, what is completed and which jobs are on hold and if so why. Operators start the first job in the queue when they commence production. The job is automatically turned green. Supervisor who is managing multiple work centers will be able to see which job the operators are currently working on. If there is a problem – non-availability of material, machine break down, operator unavailability etc…- then the operator can put the job on hold and enter the reason for doing so. It will automatically turn the job to yellow. Supervisor will be able to see these jobs and then address the situation. For e.g. if it is inventory problem, then he can rectify the problem and then reset the job so that operator can pick it back up. The module can be configured such that operator cannot start the second job before completing the first one. Also the system can force the operator to go in only the defined sequence if necessary.
Since the system knows the cycle time and setup time for each part, it can highlight whether the WC is over or under capacity for each day. Supervisor can reschedule (move it another day) or re-sequence (change the priority) within a single day.
Operators can do partial completion as needed. Once the job is fully completed it moves out of the queue.
Overall Equipment Effectiveness (OEE):
Both internal Kanban and Production Sequencing are pre-requisite for this module. In this module Ultriva allows users to define the physical entities with in a work center. Users can define Machines, associate one or more operations on the machines and allow users to be tied to operations. Supplying Work Centers can tie the operations to their supplying items. Instead of the Kanban signal being sent to a Work Center, it is now sent to Work Center with first operation for that item is automatically assigned. If there are several machines with in that work center that perform the same operation, then the user can select the appropriate machines prior to starting the job.
In addition to machines and operations, Ultriva has added a concept of Shifts as well. Administrators can define one or more shifts at each work center, one or more machines at the work center and one or more operations at each machine. It is mandatory for the administrators to ensure that all these parameters are defined before starting the system – one shift, one machine and one operation on the machine.
The users can log in to an operation associated with the machines to view the next job to be performed. The jobs are automatically sequenced based on predefined rules. Operator can start a job and once complete it will automatically queue itself in the next operation and so on till the last operation is completed.
One of the key principles behind the enhancements of the production module is “If you can measure then you can improve”. As the system collects data at the individual operation, machine and shift level Ultriva has developed a series of reports that takes advantage of this data.
Some of the key reports include:
- Closed Production
- Operator Efficiency
- Jobs not completed
- Hourly Production by Part
- OEE (Overall Equipment Effectiveness)
Supplier Kanban and SBR primarily manage Raw Materials. Internal Kanban manages Work-In-Process items. Customer Kanban manages the Finished Goods replenishment. Customer Kanban normally interfaces with either the Distribution Centers or OEM customers or where the plants are using VMI or consignment with their customers. Customer Kanban provides the same level of visibility, real time exception alerts and continuous improvement metrics like supplier Kanban. In addition it provides an easier way to manage FG inventory by consolidating the customer demands and a better insight in to customer’s demand patterns. This goes a long way in controlling the variances on the front end of the value chain.
Customers also get good visibility in to where their orders are at any time and assess the performance of the plants. This collaboration may lead to reduction in overall lead times thereby reducing the precious FG inventory buffer. Once the customer is involved in this automated pull process, it can also lead to higher customer retention rate.
Eliminated stock outs at over 95% of our customers. Reduced inventory between 25% to 75% at all our customers
|Company Size Solution is Targeting||> 1500|
|Open Source Solutions||No|
|Supply Chain Management (SCM)|
In the shift to a global, customer-centered economy, manufacturers must be more responsive in order to thrive. How quickly and efficiently can you change your processes to meet changing demands?
Ultriva is leading the way toward more efficient lean business practices with a practical, automated approach. We are focused on helping businesses to improve collaboration and drive streamlined processes through demand and supply—removing the traditional tiers that can slow down your operations. We do it with an execution platform that facilitates the flow of information and materials across boundaries to give you complete visibility while making better use of your time and resources.
Our modular, web-based tools are designed to complement and extend the value of the businesses systems you already have in place, such as MRP and/or ERP. Deploy them quickly in your high-impact areas—whether in finished goods, raw materials replenishment, or production management, and get an immediate improvement across the board. Ultriva offers its products as SaaS (Software As A Service) on Demand or SaaS on premise.
Ultriva's flagship product, Ultriva Electronic Kanban, eliminates stock-outs while reducing inventory levels up to 75 percent. Ultriva Lean Scheduling complements demand-driven replenishment strategies by optimizing production schedules in real time around the most variable customer demand. Ultriva Supplier Replenishment extends the replenishment capabilities of Kanban to include schedule-based replenishment, discrete POs, min/max, consignment and VMI (vendor-managed inventory) replenishment methods. Ultriva's products are in use in more than 130 plants worldwide, incorporating more than 5,000 suppliers, transacting over one billion dollars of inventory and reducing manufacturing costs for industry leaders such as AGCO, Dresser, Emerson, FRANKE, Ingersoll-Rand, McKesson, Owens Corning, Rexnord, and Trane