Using Kanban JIT Systems to Run a Startup Plant

Duration 90 Mins
Level Basic & Intermediate
Webinar ID IQW19I0965

  • Working definitions of kanban, JIT, pull system, and Drum-Buffer-Rope, with emphasis on medical device and biotechnology manufacturing
  • Introduction to the elements of lean documents and lean configuration
  • Selection of appropriate sterilization lot size - a key factor
  • Practical lot sizes for start-up medical devices
  • How to handle large-volume and offshore suppliers
  • How MRP II can help - and hinder - an effective kanban system
  • How to use kanbans to track off-site sterilization services
  • Using kanbans with external supply chain suppliers
  • Smart ways to minimize lot picking times
  • Lot picking inside a cleanroom

Overview of the webinar

Attend this webinar to learn how to set up and use kanbans, JIT, pull system, and drum-buffer-rope in medical device and biotechnology manufacturing start-up operations. Also, attendees will learn elements of lean documents and lean configuration, sterilization lot size, MRP II kanban system and how to use kanbans to track off-site sterilization and external supply chain, suppliers. Leraning Objectives are:

  • Myths about lot size and local efficiencies
  • Myths about documentation and support systems
  • An alternative way to track yield losses during product builds
  • Preparing kanban cards and bins to control both in-house inventory and external supplier inventory
  • Smart ways to track variable information using kanban cards (example lot number, PO number, WO number, due dates)
  • How to use kanbans for R&D prototype work
  • How to simplify paperwork to allow smaller lot sizes
  • Smart ways to simplify receiving a verification
  • How product shipments trigger new builds

Who should attend?

  • Project Leaders
  • Functional Managers
  • Manufacturing Engineers
  • QA Managers
  • Operations Managers
  • Supply Chain Managers
  • Purchasing Managers
  • Design Engineers
  • Design Assurance

Why should you attend?

This webinar will explain how to set up and use kanbans all the way from purchasing and procurement to receiving, receiving the inspection, component stock, work order picking/staging, assembly, packaging, finished goods, and sterilization. Combining the principles of a visual workplace with kanban bins and cards, this webinar will demonstrate step-by-step how to create a demand-pull system to achieve the right balance of inventory and throughput throughout your startup operation. The hands-on use of Drum-Buffer-Rope from Theory of Constraints (TOC) will also be covered.

Lean cannot be just about product and process. Based on the speaker’s extensive experience in the arena, this webinar will also discuss the elements of lean documents and lean configuration, since the principles of lean must permeate throughout all systems, not just the manufacturing supply chain. This webinar is essential to introducing lean principles from the company’s earliest stages.

Faculty - Mr.José Mora

José Mora is a Principal Consultant specializing in Manufacturing Engineering and Quality Systems. For over 30 years he has worked in the medical device and life sciences industry specializing in manufacturing, process development, tooling, and quality systems. Prior to working full time as a consulting partner for Atzari Consulting, José served as Director of Manufacturing Engineering at Boston Scientific and as Quality Systems Manager at Stryker Orthopedics, where he introduced process performance, problem-solving, and quality system methodologies. During that time he prepared a white paper on the application of lean manufacturing methods to the creation and management of controlled documents and a template for strategic deployment. José led the launch of manufacturing at a start-up urology products company as Director of Manufacturing for UroSurge, Inc. at the University of Iowa’s business incubator park in Coralville, IA, creating a world-class medical device manufacturing operation, with JIT, kanban systems, visual workplace and lean manufacturing practices. José worked for 10 years at Cordis Corporation, now a Cardinal Health company, where he led the successful tooling, process development and qualification of Cordis’ first PTA (percutaneous transluminal angioplasty) catheter. His medical device experience includes surgical instruments, PTA & PTCA dilatation and guiding catheters, plastic surgery implants and tissue expanders, urology implants and devices for the treatment of incontinence, delivery systems for brachytherapy, orthopaedic implants and instruments, and vascular surgery grafts and textiles.

During his time at Cordis, José managed the Maintenance and Facilities Department, taking that operation to a level rated as “tops” by the UK Department of Health and Social Services (DHSS) during one of their intensive audits. Jose managed Manufacturing Engineering as part of the Guiding Catheter Core Team of managers, a team that took the Cordis Guiding Catheter business to lead the market, bringing it up from fourth place. By introducing world-class techniques, the Guiding Catheter design and manufacturing was completely re-engineered for robust design and tooling, under Jose’s leadership. He was also instrumental and played a leadership role in the complete re-engineering of the Tooling Control System, including design drafting, the tool shop and technical support. Wherever he has worked, he has a track record of introducing world-class methodologies such as Kepner-Tregoe, Taguchi techniques, Theory of Constraints, Lean Manufacturing, Five S (Visual Workplace), process validation to Global Harmonization Task Force standards, and similar approaches.

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