The 2-box principle is the most powerful way of avoiding line stoppage due to material shortage. As the name implies, the fundamental idea is to provide two boxes of each material at the assembly line. Once a box is empty, it triggers the line feeder to supply new material to the line.
Why do you have to implement a 2-Box Principle?
without 2-Box Principle
with 2-Box Principle
How do you implement a 2-Box Principle?
To be able to place two boxes at the assembly line, the shelf must have at least two slots per part number with fixed locations and one additional slots for empty boxes. If the material handler’s cycle time is too high, increase from 2-boxes to 3-boxes.