1. MANAGING SYSTEMATIC PRODUCTION “ Working managers, not managed workers,” is the way of the future UNDESTANDING DRUM – BUFFER - ROPE

2. DRUM: THE WEAKEST LINK ( PERIOD ) THE SHOP CAN ONLY GET SO MANY LABOR HOURS THROUGH THE PAINT BOOTH IN A DAY OR WEEK. WE TRY TO STUFF A MARSHMELLOW IN A PIGGY BANK EVERY DAY ! DON’T WE? SAY YOUR PAINT BOOTH IS YOUR PIGGY BANK / DRUM THIS IS CALLED THE DRUM: THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.

4. FIXING OUR SYSTEMS “NAIL THEM DOWN” What is gate control? Understanding Replenishment Buffer What is the drum buffer? Understanding the drum What is the shipping gate? How do we Rope / tie it all together GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER

10. SYSTEMATIC PRODUCTION VIEW Replenishment buffer management is key to systemic warehousing and distribution GATE DRUM BUFFER WIP DRUM SHIPPING BUFFER REPLENISHMENT BUFFER STATE FARM AIG GEICO

11. SYSTEMATIC PRODUCTION VIEW REPAIR WORK COMES IN TO YOUR SHOP WE WILL CALL THIS YOUR PIPE LINE OR FUNNEL STATE FARM AIG GEICO

13. Gate control allows Constant Work-In-Process , and designates a control strategy that limits the total number of labor hours allowed into the system at the same time. The hours are released as they are processed at the consumption rate of the beat of the drum until they wind up in the last buffer as finished goods ALL OF THE WIP BETWEEN THE GATE AND THE DRUM CONSTITUTES THE DRUM BUFFER.

14. DRUM: THE WEAKEST LINK IS THE RATE LIMITING STEP. THE DRUM BEATS OUT THE PRODUCTION RATE FOR THE WHOLE SYSTEM . IN THE BODY SHOP THE DRUM IS THE PAINT BOOTH. WE ARE LIMITED TO HOW MANY UNITS OR HRS CYCLE THOUGH IT A DAY OR WEEK. THE DRUM BEATS OUT THE MAXIMUM RATE AT WHICH THE SYSTEM CAN WORK.

15. SHIPPING BUFFER IS DISCRIBED AS FOLLOWED: 1 REASAMBLY OF THE VEHICLE 2 DETAIL 3 QUALITY INSPECTION OF FINAL PRODUCT SHIPPING BUFFER

16. Thank you for giving me the opportunity to train your company in understanding Systematic production. Now that you understand the process we can now find your capacity and work on improving your through- put and reduce cycle time. PRESENTED BY. RANDY S FERRESE SR 824 BLUEBIRD CIRCLE MAYS LANDING ,NJ 08330 [email_address] 609 553 4244