Aisles full of transfer carts—blame planning for overload. Count and find too few carts or fixtures, or good carts piled in corners. WIP level is a function of logistics containers: no cart means floor stock; floor stock is invisible; invisible drives overproduction. Smart manufacturing quotas, locates, and binds carts, bins, and fixtures to work orders before pull systems.
High WIP—count carts and racks first. Short carts mean systems only photograph floor piles.
Containers Are Moving Stations
Each container type has quota and address. Empty carts return to supermarket; full carts follow work orders. Loss and overtime occupancy alert. New lines size containers before kanban.
- No unnumbered containers on line; no personal cart hoarding.
- Container shortage cannot mean cartons and floor as permanent WIP homes.
- Repair and scrap through ledger—avoid books showing carts that are not on floor.
Quota Before More Software
The XYN digital intelligence system binds containers to work orders—WIP countable by cart. Containers sufficient and in place give digitization an object; scattered parts mean scans only number chaos.
Count empty and full carts at line side today. Stations short on empty carts—fix quota before lowering WIP targets.
