Working for a while in an environment of plants and with many projects, we have encountered that materials transport inside of the plant is the case that always generates smaller or bigger problems. On the one hand, we have internal logistics workers, who often are not equipped with any modern work support system, and even if the organization has invested in the implementation of the kanban, it is usually complicated and difficult to use system. On the other hand, we have production workers for whom ordering components and half-finished products is an unwanted necessity wasting their time which should be used to realize production plan.
While analyzing the case, we have noticed 3 main factors causing internal factory transport to be inefficient, unclear and impossible to control.
With no doubt delays in the supply of components and half-finished products are the main problems occurring on the edge of the logistics-production system, and whatsoever one of the main factors of low completion of production plans. Delays cause wasting the time needed to produce planned number of components and also affect the quality of producing details and increase the number of reclamations form the clients.
The second of the main issues is misleading communication between those who order(production department) and those who deliver(internal logistics department). It often happens, that materials are delivered according to the plan. However, materials delivered are not materials that have been ordered or are not delivered in ordered quantity. This leads to even bigger delays and decreases the quality of manufactured products.
Lack of data to analyze
In constantly changing environment of the plant menaging each proccess, including material's transportation proccess is the key factor. However without neccessary data available on the spot analyzing is either very tough or even impossible.
Usually, the logistic's leader has no subordinate, who could up to date do analysis. Because of that leader constantly has to choose: whether to realize current tasks or increase process quality. Often the realization of current tasks is chosen and an unchanged process in a changing environment degrades and becomes less efficient.