Shop reports shortage; warehouse says a big batch went yesterday. Line-side lacks key parts yet piles non-key parts. Root cause is usually not total inventory—it is mismatch between request batch and delivery frequency: shop requests for safety, warehouse delivers for convenience, and WIP rises from both ends. Delivery frequency is the WIP switch—not a logistics detail.
To slim line-side, change frequency first—then debate bigger automated storage.
Request by Takt, Not Shift Safety Margin
Explode work orders into request points—minimum pack by takt or fixed window. Ban "request three days to save trips." Line-side supermarket sets max/min levels—request only below min, warehouse rejects above max. Rejection protects WIP—not shop harassment.
- Publish delivery windows—e.g., every two hours; urgent exceptions use separate channel.
- Request slips carry work order and operation; issue scans by slip—no verbal over-issue.
- Material idle at line-side beyond rule time forces return—line-side must not become warehouse two.
Warehouse Delivers by Window, Not "When Free"
If issue KPI only rewards "ship everything at once," drivers stack a day's goods on early shift. Score window achievement and mis-issue rate instead. The XYN digital intelligence system links work-order requests, line-side levels, and warehouse delivery tasks to one rhythm—shop sees next window, not "shout again." Stable frequency drops WIP to takt; unstable frequency fills even lean boards with hoarding.
Agree windows first—then discuss automated carts. Carts speed delivery—they do not set frequency discipline.
