01_upload_Intro_to_Kanban_ concepts_14_pgs.ppt
- 1. © Improvement Initiatives (used with permission of author) freeleansite.com The Lean Enterprise Lean Foundations Continuous Improvement Training An Introduction to Kanban concepts
- 2. © Improvement Initiatives (used with permission of author) freeleansite.com • 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
- 3. © Improvement Initiatives (used with permission of author) freeleansite.com Kanban Definition What is Kanban? • Card system that controls production & inventory • Visual “pull” system vs. a “black box” push system (ie - MRP)
- 4. © Improvement Initiatives (used with permission of author) freeleansite.com • 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 !
- 5. © Improvement Initiatives (used with permission of author) freeleansite.com 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!)
- 6. © Improvement Initiatives (used with permission of author) freeleansite.com • 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
- 7. © Improvement Initiatives (used with permission of author) freeleansite.com Categories of Kanban Instruction Withdrawal Kanban Production Kanban (non lot production) Triangle Kanban (for lot production) Interprocess Kanban Supplier Kanban
- 8. © Improvement Initiatives (used with permission of author) freeleansite.com 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
- 9. © Improvement Initiatives (used with permission of author) freeleansite.com 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
- 10. © Improvement Initiatives (used with permission of author) freeleansite.com • 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
- 11. © Improvement Initiatives (used with permission of author) freeleansite.com 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
- 12. © Improvement Initiatives (used with permission of author) freeleansite.com GEMBA FLOOR WALK Go and see where you could implement Kanban!
- 13. © Improvement Initiatives (used with permission of author) freeleansite.com The Lean Enterprise Lean Foundations Continuous Improvement Training An Introduction to Kanban concepts