THE PROBLEM
Too much capital tied up in service parts inventory

	The PODS line is controlled by a centralized control station.

The demand for service parts is generally lower than for parts used for new production, and unpredictable on a day to day basis. This daily unpredictability required that relatively larger inventory of service parts be maintained in order to ensure the desired levels of service parts availability (fill rate).

IF service parts could be quickly produced on an as needed basis, these inventory levels could be reduced, while still maintaining the desired availability.

BUT quickly manufacturing parts in small, random quantities is historically not efficient nor economical.

THE SOLUTION
Parts on Demand System (PODS)

Parts on Demand System or PODS, a unique manufacturing system developed by GTS just for service parts manufacturing, solves the problem for low volume, random quantity requirements. Just as it's name implies, Parts on Demand System is a production methodology which enables quick, efficient production of service parts in ANY quantity, even singly.

HOW IT WORKS

Component parts are kept in one or more of the bin pairs located to the right, front, and left of the operator.

PODS uses elements of Lean Manufacturing Techniques, Demand Flow Technology (DFT), Just In Time, Total Quality Management (TQM), Paperless Workstations and Computer Assisted Work Instructions.

 
THE ZERO INVENTORY SOLUTION

While the PODS line makes it theoretically possible to operate with ZERO service parts inventory, most service managers don't feel that lucky. It is, however, very feasible to use PODS to significantly reduce your service parts inventory while still maintaining the targeted fill rate.

Specific work instructions appear on a display located immediately over the workstation.		Adjacent workstations are located on the opposite sides of the line in order to give unhindered access to the backs of the sloped shelves for restocking.

ADVANTAGES OF PODS

• PODS eliminates set up time and "parts picking" for small runs.
  
  
• The operator only follows instructions on the screen each time. It does not matter if the next assembly coming down the line is identical or completely different from the previous assembly.
  
  
• Entry level operators and temps can quickly be trained to follow the instructions on the screen. This permits great flexibility to expand or contract when production volume increases or decreases.
  
  
• Additional products can be easily added to PODS.
  
  
• Our customers can operate with lower service parts inventory levels, while maintaining higher fill rates and greater customer satisfaction.

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