IBM Systems Magazine, LANSA Review- May 2014 - LR4

Kawasaki's assembly staff
goes Mobile
Kawasaki Motors Manufacturing Corp., U.S.A.'s consumer products division in Lincoln,
Nebraska (KMM), has replaced its card-based Kanban system with an electronic
solution. The new eKanban solution was developed by KMM's in-house development
team and integrates with KMM's IBM i-based ERP system. Assembly and warehouse
staff access the solution from iPads with native mobile apps developed with LongRange
from LANSA, a mobile app toolkit for IBM i developers. Staff on the floor also use
the mobile apps for cycle counting, and other warehouse and assembly related tasks.
Jay Kamradt, Information Systems Supervisor at KMM, says "The solution is saving
over US$ 3,500 per day and we expect very quick ROI. Our developers are very
experienced at enhancing the functionality of our ERP system, which was the largest
part of this project. Initially we didn't think we had the skills to develop the native
mobile apps ourselves, as LongRange only became available towards the end of our
project. The mobile apps were developed by 3 of our IBM i developers. We launched
our first series of apps within 2 months of going through the LongRange tutorials."
The Challenge
KMM manufactures All-Terrain Vehicles
(ATV), Personal Watercrafts (Jet Ski®), Utility
Vehicles (Mule™), Recreational Utility Vehicles
(RUV - Teryx™) and wheels for ATVs and
utility vehicles. These products are shipped
throughout North America and exported to
Japan, Europe, Australia, New Zealand and to
other locations around the world.
KMM operates on a 'just-in-time' basis to
eliminate expensive warehousing. In this lean
manufacturing environment, Kanban is used
to signal the need to move parts from the
warehouse to the production floor.

Traditionally Kanban is implemented using
cards that are attached to a parts box. When
a box at the assembly line becomes empty,
it is returned to the factory store with the
Kanban card still attched. The factory store
then replaces the empty box at the assembly
line with a full box and contacts the supplier to
replenish the amount of parts mentioned on
the returned Kanban card. When the supplier's
order is delivered into the factory store, the
Kanban card is attached to the box, completing
the cycle. The process is meant to provide the
exact number of parts required, with just a
small buffer of spares.

The mobile apps play a key role to record and track inventory on the assembly lines.
4

LANSA Re vie w

Until recently, KMM used a manual Kanban
card system at its 4 assembly lines. KMM uses
up to 4,500 Kanban cards per day and the
labor costs of staff handling those cards was
estimated to be $3,000 per day.
There were other inefficiencies to the
manual card system as well, according to
Kamradt. "Cards could get lost, resulting in
late delivery of parts. Also, there was no way
of stopping staff from turning in Kanban cards
early. Workers were sometimes hoarding 3 to
4 days of inventory at the assembly line, when
they only needed a buffer of 4 hours."

"The solution is saving over
US$3,500 per day and we
expect very quick ROI."
"We have the in-house experience to
customize our ERP solution, but we didn't
think we had the skills to develop native mobile
apps ourselves. The project was well underway
when LANSA made its LongRange mobile
development tool available and we were keen
to get on the beta program."

eKanban Efficiencies
With some guidance from a LANSA
professional services consultant, KMM
developed its first LongRange mobile app. The
app allows the assembly inventory specialists,
nick named parts-police, to scan-in or enter
deliveries of parts at their assembly line and
to monitor the balance of parts. When the
assembly of a certain unit starts, the ERP
system is notified and it allocates the parts
needed. Since it is now recorded exactly how
many parts are kept at each assembly line,
the allocation will automatically trigger a pick
transaction when the inventory of a part at a
line falls below a specified minimum.
Kamradt explains, "Previously once parts
left the warehouse, we didn't have any means
to record where on the assembly floor they
went or how many were accumulating there.
Now we have an accurate real-time recording
of parts, whether in the warehouse or on the
assembly floor."
"Having the mobile app allows for total
accuracy. We now keep only 4 hours worth of
parts on the floor and for bulk items even less.
In addition, we now have a better and safer
work environment. In the past the assembly


http://www.kawasaki.com

IBM Systems Magazine, LANSA Review- May 2014

Table of Contents for the Digital Edition of IBM Systems Magazine, LANSA Review- May 2014

IBM Systems Magazine, LANSA Review- May 2014 - LR1
IBM Systems Magazine, LANSA Review- May 2014 - LR2
IBM Systems Magazine, LANSA Review- May 2014 - LR3
IBM Systems Magazine, LANSA Review- May 2014 - LR4
IBM Systems Magazine, LANSA Review- May 2014 - LR5
IBM Systems Magazine, LANSA Review- May 2014 - LR6
IBM Systems Magazine, LANSA Review- May 2014 - LR7
IBM Systems Magazine, LANSA Review- May 2014 - LR8
IBM Systems Magazine, LANSA Review- May 2014 - LR9
IBM Systems Magazine, LANSA Review- May 2014 - LR10
IBM Systems Magazine, LANSA Review- May 2014 - LR11
IBM Systems Magazine, LANSA Review- May 2014 - LR12
IBM Systems Magazine, LANSA Review- May 2014 - LR13
IBM Systems Magazine, LANSA Review- May 2014 - LR14
IBM Systems Magazine, LANSA Review- May 2014 - LR15
IBM Systems Magazine, LANSA Review- May 2014 - LR16
IBM Systems Magazine, LANSA Review- May 2014 - LR17
IBM Systems Magazine, LANSA Review- May 2014 - LR18
IBM Systems Magazine, LANSA Review- May 2014 - LR19
IBM Systems Magazine, LANSA Review- May 2014 - LR20
IBM Systems Magazine, LANSA Review- May 2014 - LR21
IBM Systems Magazine, LANSA Review- May 2014 - LR22
IBM Systems Magazine, LANSA Review- May 2014 - LR23
IBM Systems Magazine, LANSA Review- May 2014 - LR24
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