Cadel S.r.l. is an Italian company with over 60 years of experience in designing, producing and distributing wood burning cookers, wood stoves and pellet stoves all over Italy and Europe. In recent years the Company has developed considerably, growing from small artisan workshop to real factory, with 14,5 million euros turnover and over 17.500 finished goods produced in 2013. The production system, distributed over three plants, is deeply vertically integrated and makes use of the most modern technologies of sheet metal working. The strong production tradition and the passion for the product have allowed Cadel to boast over the years loyal customers that still buy and remain faithful to its quality products made with top-quality materials and design.
KanbanBOX is being used by Cadel since March 2012. After an initial test phase, that lasted just over a month and a half and was focused on setting the flow of semifinished products between the internal carpentry and the rest of the production areas, KanbanBOX has been extended to the whole Supply Chain, to both external suppliers and to in-house production. Today Cadel manages in KanbanBOX more than 2200 components produced internally and more than 800 purchased from external suppliers. Over 50 key suppliers share all the information about the status of kanbans. In fact, they have access to KanbanBOX so they can check in every moment how many kanbans are still available in the Cadel supermarkets and how many need to be supplied.
By reading the barcode written on the cards, Cadel replenishes more than 250 kanban orders every day from both internal and external suppliers.
The implementation of KanbanBOX has allowed to achieve considerable performance improvements in the efficiency of company resources involved in Kanban management. This increase in efficiency has involved mainly the Operations Manager, the Materials Planner, the warehousemen and the operators of the assembly lines. First of all the time to calculate, to size, to create, to print and finally to activate the Kanban system for a single component has been drastically reduced. Before KanbanBOX these activities required more or less 20 minutes for each component. Today the activation of a kanban takes less than two minutes, drastically reducing time and costs for Kanban management. Secondly, also the maintenance aspect has been heavily modified, both in terms of burden and frequency. In fact until 2011 the number of kanban cards was recalculated one or twice a year, actively involving about 3 resources: the Materials Planner, a warehouseman and a team leader. Now, thanks to KanbanBOX, the maintenance of kanbans is run continuously, with resizings released even twice a month if necessary. Moreover, maintenance in Cadel does now require just one person (the Materials Planner). Thanks to the "disposable kanban card" system, the resizing activities do not interfere with the work of production operators and warehousemen. With regard to purchases, the first consequence has been the incredible reduction in the amount of time dedicated to the management of the errors generated by external suppliers. The operativity of the Materials Planner – already optimized and standardized by the preexisting “traditional” Kanban management system – switched from recalls and solicits to the optimization of the flow and stocks. For many components that belong to the A-class for value/consumption, the stock has been reduced up to 50% in addition to what had already been achieved through the “traditional” Kanban system. Communications with suppliers have considerably decreased and so it was for the solicits: now the status of the total stocks is fully visible and transparent between the two parties. Last but not least, it is worth noting the increased rapidity with which Cadel is now able to identify and fix potentially dangerous stock-out situations. The tangible result in a few months has been more than the 40% of reduction in the number of lines stops, compared to the beginning of the same year.
“… we chose to use KanbanBOX to have a computer tool capable of exploiting the strengths of visual management, but without the burden due to the maintenance and management of a traditional Kanban system. Note that today Cadel manages 2200 kanban loops for the items of in-house production and about 800 for goods purchase. The problem was particularly connected to the strong seasonality of our product that, in a traditional Kanban management system, requires constant maintenance depending on the time of the year.
Currently the system is fully active for the in-house production with a system of disposable kanban cards that, integrating the reprinting in the process of value creation, allows better control on materials flows. On the purchases front, from week to week we are integrating new suppliers in the system in order to gain better control on their work and to monitor the status of orders in real time.
From the beginnig of 2013 KanbanBOX is fully integrated with our ERP system, so we are able to automatize the information flow also for our Administration department. Thanks to the statistics at user disposal, that give a better and realistic view of the real consumption, we are now working to directly enable the warehousemen to do autonomously the re-sizing of kanbans. For the future we expect to achieve an improvement of the production efficiency and a further reduction of circulating stocks.”
Sintesia helps companies along the lean transformation of their production and business processes and the building of their lean organization. Sintesia offers lean consulting services and kanban management software solutions.
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