They know to tackle all purple jobs before working on any blue jobs. Following the tenets of demand-pull manufacturing, a color that is, group of jobs progressing forward triggers support processes into action. Instead, people took a step back and started asking basic questions. Instead of being focused only on the job in front of them, everyone now is focused on velocity, or how fast jobs flow through the system.
Note the blue and pink tags and job packets, which determine the sequence of release to the next operation. Instead, following the tenets of demand-pull manufacturing, downstream processes pull orders from upstream. The company got there by manufacturing in sequence and focusing on job velocity. Some errors, like failing to order long-lead-time items, led to significant delay. It now takes them less than half the time. Whatever the mistake, a job is flagged, while the remaining jobs in a color progress forward to assembly. But with everything visual, the story changes. The Dover Corporation is a multi-billion dollar, global producer of innovative equipment, specialty systems and value-added services for the industrial products, fluid management, engineered systems and electronic technology markets. Making things even more complex was the diverse material mix. Instead, people took a step back and started asking basic questions. When they get that next color, the team lead looks at the group of jobs within the color and decides how best to sequence them, so that everything as a group not individual cases is finished in the least amount of time possible. The fabrication and assembly times were just too varied and unpredictable. Everyone also keeps an eye on the colors throughout the plant. If he sees that WIP carts in front of the next manufacturing step exceed a certain number, he knows that he needs to move downstream to help clear the bottleneck before it grows any larger. Even after being fed parts from the laser, the panel bender still has excess capacity. The timing is such that as the purple display case reaches the refrigeration installation station, the refrigeration subassemblies go right into the main display case assembly. Parts are nested in such a way that one color emerges from cutting in the most efficient way, with maximum material utilization—but again, all within the same color. Produce a hour case followed by a hour case, and the hour case would sit on the production line like a bump on a log or a clog in a pipe. To remedy this, the company began interviewing vendors and adopting vendor managed inventory VMI for items in which it made sense to do so. They know to tackle all purple jobs before working on any blue jobs. Dover promotes talent development from within and in doing so offer high potential candidates the opportunity to advance by moving to other Operating Companies in the Dover Corportaion to gain the needed experience to continue to move forward with their career. From there the operator scans the job packet bar code into the panel bender, which loads the program and moves the tools as the blank is loaded into the system. The thinking was that racking more and more parts was just the nature of the beast. For the pull system to work, the team knew they needed significant capacity in sheet metal cutting and bending. Back then it took 13 weeks for an order to ship, and people needed all seven days of the week to get many of those orders out the door. If none exist, they move on to the next color.
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