I wrote my MSc thesis at Continental Automotive Hungary Kft, about the development of automotive electronics production lines. The improvements were carried out using Lean tools. The master's thesis goal was to find a product and a pruction line which can be easily converted to pull production system. I have done the improvements using Lean tools. My first task was choosing a production line, which easily can be converted with a minimum financial investment. There are a lot of influencing factors of choosing an appropriate production line, such as production quantity, complexity of the product and the life cycle. After selecting the appropriate product and production line, I create the current state Value Stream Map (VSM) of the production line. My next goal is to create a future state VSM where the production lines are perfect. In the future state VSM I create a pull manufacturing line, with a supermarket in the end. The size of a supermarket is the most importent part of a pull system because this is the controlling part of the manufacturing processes. I use the RE+LO+WI+TI+SA process to calculate the size of the supermarket. First of all during the calculation process I compute the replenishment time of a magazin.
Next step is to define the lot size of the manufacturing. After that I calculate the withdrawal peak, the maximum number of product that the customer can bring.
There are big differences between 3 and 4 shifts what I have to fill, these differences are called time gap.
The last part I have to calcule is the safety stock, what is an additional number of product, what we can use during unplanned break downs.
The size of the supermarket is 11 palettes according to the calculation I used. Using this supermarket our manufacturing become more flexible and more balanced. We are able to react much faster to customers changes using supermarket at the end of our porduction lines.