Re:The global chip shortage is starting to have consequences
by p_l on Monday May 10, 2021 @02:52AM
(#27103375)
(probably wrongly worded)
Wouldn't toyota model essentially set a required buffer size in kanban, essentially ensuring a certain level of stock decided upon by risk management?
The pull flow would then ensure that the stock fluctuates around that value instead of being driven to 0, because taking a "card" out of stock might trigger purchasing of more stock?
Re:The global chip shortage is starting to have consequences
by avs733 on Monday May 10, 2021 @09:21AM
(#27105685)
Toyota (for example) doesn't get the chips directly, this is about visibility/planning/management of your vendor's vendor's vendor's. Those chips (Tier 3+) become boards (Tier 2) become center consoles (Tier 1) that an OEM installs.
The question isn't how stock is tracked or risked, its who is responsible for it.
Not holding inventory is great for a lot of reasons, but it is a calculated risk...Toyota learned from experience that if they want to do it, they need to understand risk all the way up their supply chain. They largely aren't having this problem. They de-risked certain things because they really treat TPS and everything associated with it as a philosophy not a set of heuristics that should just be implemented blindly. Manufacturing something is all tradeoffs...there is (almost) nothing with a universal upside. Sure I want to hold less inventory, but JIT is actually about manufacturing time, not inventory. If I have NO inventory and NO ability to get inventory my manufacturing time goes up while I wait with my thumb in the fertilizer pipe.
I've worked with a couple of manufacturing plants (and consultants...) that treat 'JIT' inventory management as something that can simply be pushed off to vendors and then the upside of less inventory enjoyed. They have specs and forms and certification and paperwork...but nobody looks at it. Those are the companies struggling now. They outsourced without fully understanding the risk of the outsourcing. Usually this doesn't bite the world, it bites one or two companies that relied on a certain part (someone misses an EOL notice) or a certain vendor (who goes bust because the owner's grandson ran the thing into the ground). It's like my students who make choices in the first week of the semester that seem minor...and then are frustrated when it effects their grade at the end of the semester (sorry, too much grading this week)
[0] https://www.autoblog.com/2021/03/09/toyota-how-it-avoided-se...