How to Set Up a Supermarket

Supermarket

“Designing & Implementation”

Guide Book

INDEX

1) Supermarket Concept………………………………………………...3

2) Supermarket Concept- Benefits……………………………………....4

3) Steps In Designing & Implementing Supermarket…………………...5

i. Data Gathering………………………………………………..5

ii. Data Analysis & Planning…………………………………….6

iii. Execution……………………………………………………...6

iv. Control………………………………………………………...7

4) Process Flow………………………………………………………….8

5) Detail Description……………………………………………………10

6) Kanban cards

Guidelines for designing Kanban cards……………………………...16

7) Standard Operating Procedure (SOP)………………………………..18

for Supermarket

i. Two-Bin System based………………………………………18

ii. ROP Based…………………………………………………...20

iii. Pure simulation based………………………………………..22

8) Special Instructions for all the items………………………………...24

9) Regular Audit of Supermarket……………………………………….24

10) Physical Layout Considerations……………………………………...25

11) 10 Golden Rules for Storage…………………………………………27

12) Requirements of Supermarket (Pull) System in a Supply Chain….....28

13) Further Requirements………………………………………………...29

14) Visual Management Considerations………………………………….30

15) Supermarket System (Pull) – Some Issues…………………………...31

Supermarket concept

Supermarket is a material sourcing & handling system which is based on the Just In Time (JIT) and Pull System concepts, raw materials are physically stored near to the Point of Use (POU) to support continuous flow manufacturing (CFM). Material replenishment process is enabled by pull signal from production operators (with the consumption of Kanban Quantity) and the Water-spider (Material Handler) deliver materials to the workstation via pre- defined quantity, material- delivery routes and standard work sequence.

Supermarket Concept – Benefits

• Reduced working capital resulting in much higher profits.

• Improved Material availability...