01_upload_Intro_to_Kanban_ concepts_14_pgs.ppt

KANBAN

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The Lean Enterprise
Lean Foundations
Continuous Improvement Training
An Introduction to Kanban concepts

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•Learn what Kanbans are and the
different way the terminology is
used in industry
•Understand how to setup a
kanban
•Understand how to implement a
kanban system
Objectives

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Kanban Definition
What is Kanban?
•Card system that controls production & inventory
•Visual “pull” system vs. a “black box” push system (ie -MRP)

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•Kanbans are All Around Us
•Kanbans are Inventory
•Inventory Is waste (costly!)
•Goal Is To Minimize Inventory In
Kanbans And Eliminate If Possible
Basic Kanban (Pull signal)
Ultimate Goal of Kanban is to not
have a KANBAN !
One-Piece Flow is the Answer !

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Benefits of Kanban
•Primary
–Eliminate over-production, the #1 waste
–Produce only what is ordered, when ordered, & quantity
ordered
•Secondary
–Increase flexibility to meet customer demand
–Reduction in scheduling by Production Control &
Manufacturing
–Competitive advantage by sequencing shipments to customers
(what they want, when they want it, in the order they want it!)

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•No Cards
–Visual (Tape On Floor)
–Two-Bin or Bin Systems
–Supplier Containers
–Painted floors, i.e. squares, circles
•Card Systems
–Electronic Kanbans -Fax or Emails
–Warehouse Or Parts Racks
–Kanban Boards –Magnetic or Cards
–Containers
–Flow Thru Racks
–Supplier Boxes
Kanban Options

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Categories of Kanban
Instruction
Withdrawal
Kanban
Production Kanban
(non lot production)
Triangle Kanban
(for lot production)
Interprocess
Kanban
Supplier
Kanban

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Production or (In-Process)-Kanban
–Provides production instructions for the work center
–Tells the workers exactly the quantity and the type of part to
produce
–Used for work centers that produce only one part number or
have minimal setups in spite of multiple part number
production
•Rectangular –one piece flow production
•Triangular –for small lot production
Withdrawal-Kanban
–Inter-Process Kanban
•Delivers order for parts from a preceding process
•Specifies quantity and type of parts to deliver from
Location A to Location B
–Later replenishment system –kanban are filled from
suppliers finished goods shelf
–Sequenced withdrawal –supplier sequences parts in
reverse order for truck loading
–Supplier Kanban
•Same as an inter-process Kanban, except it signals
conveyance of part from an outside supplier
Kanban Types

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Job order-Kanban
–Issued for each job order
Through-Kanban
–When two processes are very close, it doesn’t make sense to issue two
Kanbans. Used where one process directly feeds (conveyor) the next
process.
Common-Kanban
–Where a withdrawal kanban is used as a production ordering kanban if
the distance between two processes is very short and share the same
supervisor.
–
Emergency-Kanban
–Temporary, when there is a defect or problem, can be withdrawal or
production
Other Kanban Types

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•Never Pass on A Bad Part
•The Parts Are Always Withdrawn From The Prior
Process
•Produce Only What Is Necessary To Replenish The
Quantity Withdrawn
•Level Load Production, Rapid Changeover, Small Lot
Production, Zero Defects
•Kanban Is Used To Fine Tune (Not Provide For Major
Changes)
•The Process Must Be Capable Of Producing Good Parts
(Rational And Stable)
•Need Efficient Methods Of Transportation, Shortest
Routes Possible
•Disciplined Organization
•Nothing Is Made or Transported Without A Kanban.
•Kanban Cards Always Accompany the Parts
Themselves.
•The Number of Kanbans Should Decrease over time.
Rules of the Kanban

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Kanban
–An Information System That Signals the
Need To Start An Event
–Name For Each Individual Signal (Card
Or Otherwise)
Purpose
–Control The Flow of Production by
Providing Information Which
Interconnects Upstream And Downstream
Processes At Every Level
Implementation
–Usually A Piece Of Paper in a Vinyl
Envelope Or Container
–Outline Markings On The Floor
–Most Common Is Two -Bin System
Summary Definition

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GEMBA FLOOR WALK
Go and see where you could implement Kanban!

13. © Improvement Initiatives (used with permission of author)
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The Lean Enterprise
Lean Foundations
Continuous Improvement Training
An Introduction to Kanban concepts