KANBAN_CHEM

3M Confidential.1 11 December 2015. All Rights Reserved.© 3M
Kanban System Project – Chemical Department

 Eliminates past practices of bulk ordering – orders were for the most part placed just a few
times a year.
 Reduce Warehouse footprint by 17 Pallets or 5 warehouse spaces
 We have many other products we order this way = this takes up an enormous amount of
space in the warehouse
 Excess quantity of supplies means they cant be stored together = No visual way to verify
quantities
1st Kanban item in Chem will trial 8 oz Sample Jars
 Less space taken up in warehouse, can visually see on hand quantity in the 1 x dedicated
space = Much less chance of stocking out because its very easy to see what we have and
when we need to re - order
Why Kanban for 3M CHEM??

KANBAN for 8 oz Sample Jars
Max: 16 boxes Max: 24 boxes Max: 42 boxes Max: 36 boxes
Avg. Plant usage
Weekly boxes = 120
- 240 Boxes every 2 wks
Min on hand: 2 x Pallets (348 boxes)
Max on hand: 4 x Pallets (696 boxes)
Understanding
How our Kanban will work
CHEM Supervisors -
Each bld has a dedicated rack/space for sample jar boxes. But Why?
- visual indicator of what is actually on hand in the bldg.
Why is knowing what is on hand important?
- There is a 2 week lead time to re-order from vendor
- Inventory/Purchasing re-orders when 2 pallets remain – leaving aprox 3x weeks on hand;
needs continue to supply every bldg. while waiting for next shipment
- Operators only take what they need for that shift to their work station. (If they will need 2 or
3 jars, don’t take whole box of 12. If all BCs running did that we could have 3-4 days on
hand randomly scattered in the bldg.)
- Pulling more than needed to a bldg (like a pallet)will stock out another bldg
Kanban cards (an ordering card) very easy to use , MS Word
-name of item ie “8 oz sample jars”, 11-digit 3m ID, and a blank space for quantity to be
written in
Shift supervisor on Friday ‘s AM checks the building’ sample jar location.
- Fill out Kanban order card for the quantity needed to get the supply back to the posted
max. (ex. the rack has 10 boxes left in the rack and the label says “max” is 24 boxes, the
order would be placed for 14 boxes.)
- No Later Than 845am on Friday’s - Supervisor places filled out kanban order card in the
building Mail box outside.
Warehouse - providing a driver “milk runner” that will make a run to each bldg.
- Run will be done on Friday day shift (No earlier than 9am – no later than 2pm)
- Driver collects all kanban cards from the mailboxes.
- After kanban cards are collected, driver pulls the needed items from warehouse kanban.
- Driver then delivers orders back to the building the same day.
(Buildings are responsible to move boxes from kanban re-supply drop off shelf and stock
back on designated Kanban shelf.)
Future State - Eventually the card will contain multiple items for Kanban re-supply (ie
Pails & Pail Liners, Drum Liners, yellow sample jars, poly sample jars etc)
• The “milk run” done by the warehouse driver will increase to multiple days a
week due to the increased number of re-supply items. Number of times per
week is TBD
Main Kanban Supply (Bld 26)
• When the quantity reaches the “Min” of 2 Pallets
(enough to supply plant for 2 weeks + 30% overage ) an
order is placed to vendor for 4 x Pallets to refill the “Max”
- Lead time of 2 weeks to receive pallets from vendor.
- Jill / Mary will need to re-order aprox. every 6-8 wks
Weekly Avg. usage (w/ 20% overage)

Milk Run route
Bld. Mail box
location
1
4
3
2
Finish
START Kanban
Supplies
• First milk run - driver follows route to
pick up Kanban resupply cards staring
at bld 16 (currently not set up so will
skip 16 for now) and end with bld 25.
• The driver then returns to bld 26 after
picking up last kanban card from bld
25.
• Driver picks up the needed supplies
from Main Kanban supply area
• Second milk run – once supplies
are loaded up, driver follows same
route again, starting with bld 16
(currently not set up so will skip 16 for
now) and end with bld 25, dropping off
the supplies at each buildings
designated Kanban re-supply drop area
(see slide # 7)
Re-Supply Drop
Location

KANBAN Mail Boxes
 Mailboxes are mounted in a locations on the buildings that facilitates easy pick-up for the warehouse “milk runner” pick
up cards (see next slide for locations)

Locations for Kanban Mail Boxes in Chemical
Supervisors will fill out Kanban order card
and put in the mailboxes

Kanban Order Card – MS word
• Location of Card template:
• Print off Kanban card template
• Fill out Qty needed, bldg, name and
date

Re-Supply Drop Off Locations for Kanban Supplies
- These locations in each
building are where the
Warehouse Milk Run driver
will drop off the 8 oz sample
jars when they return with
the orders

BLD 6 – Updated Respirator policy
Warehouse drivers will be able to drop off supplies inside Bld 6
garage door during Cross-linker run without having a respirator.

 Bldg 6 (16 max)
― 1 x dedicated rack location
― 2nd Floor – 16 box Max
 Bldg 7 (24 max)
― 1 x dedicated rack location
― 2nd Floor (max:24 boxes)
 Bldg 25 (42 max)
― 2 x dedicated rack locations (still need to label one on 3rd floor)
― 1st & 3rd floor (max:30 x boxes 1st flr, 12x on 3rd floor)
Dedicated Rack Locations inside the Chemical buildings

Before and After Bldg 6
Bldg 6, 2nd floor main location Kanban Supplies

Main Warehouse Kanban
A Dedicated Kanban
space has been
allocated ~ 1 X Space
containing the
required 4x pallets
for main Kanban
• Space still needs to be
Labeled “8 oz Sample Jars”
• Still needs a painted re-order
trigger line (when 2x pallets
are remaining in space)

KANBAN_CHEM

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