Kanban strategies
Download as PPTX, PDF1 like1,195 views
The document discusses the KANBAN system for replenishing materials in a lean production process. It describes different types of KANBAN including in-process KANBAN and multiple-card KANBAN. The single-card KANBAN system uses two containers that are replenished when empty, maintaining steady production. Replenishment points should be close to the production line. Multiple-card KANBAN uses separate cards to signal moving and producing materials, with a wait/work board to prioritize production based on consumption signals.
Kanban strategies
- 1. The KANBAN StrategiesSubmitted By:ASHUTOSH KUMAR JHA (91011)
- 2. NISHANT SINGH (91039)KANBANKanban is the Japanese word for card.
- 3. The card is the authorization for the next container of the material to be produced.
- 4. A sequence of Kanban pulls material through the process.
- 5. A signal is seen by the producing department as authorization to replenish.Types of KANBANIn Process Kanban
- 7. Multiple-card KanbanThe single-card KANBAN systemTwo identical containers are filled with an equal amount of parts.
- 8. The empty container becomes the signal for replenishment while other container used for production.
- 9. The last part in the second container will be consumed just as the first container is returned from being replenished.Consumption and Replenishment PointsThe replenishment point should be located within a short distance from line.
- 10. RIP is the primary replenishment location for the storage of materials used for refilling.
- 11. Replenishment of RIP can occur from two points:
- 12. Stockroom
- 13. SuppliersReplenishment PointTime taken to retrieve the signal container, transport the container to replenishment point, refill the container and return to consumption point.
- 14. Determine the inventory remaining in second container. Daily Demand * Replenishment Days Packet Size= Quantity
- 16. Replenishment PointTradeoff is required because minimizing the Replenishment time too much results in increased velocity of material leads to increased material handling cost and traffic.
- 17. Review daily demand.Consumption Point1DayReplenishment PointReplenishment PointReplenishment Point3Day10DayLineRIPCentral StoresSuppliers
- 18. Key IssuesInitial setup can represent significant amount of work
- 19. Signal can of any form
- 20. Labeling should be keeping in mind system design and operator independent
- 21. Containers should be of calculated size and not larger or smallerIn-Process KANBANClear and visible signal placed on the downstream side of operation to signal the upstream operation to perform another Takt time amount of work.
- 22. IPK provides a temporary parking space for units completed faster than the consuming workstation.
- 23. Basically used to pace up the production as per the customer demand.In process KANBAN(Purpose)To accommodate minor imbalances on the Lean line.
- 24. To maintain the correct sequence of production to meet customer demand.
- 25. To alert the operator when it is time to ‘flex’ to the next workstation to help achieve balance on the Lean line.Multiple Card KANBANUses separate cards to signal move and produce
- 26. Used in shared manufacturing processes or processes with long replenishment time
- 27. Multiple containers required as the replenishment quantities is very large
- 28. Multiple cards are accumulated in a prescribed number to be considered as signal
- 29. A ‘Wait/ Work’ sequencing board is used to accumulate these signalsWait/Work Sequencing BoardUsed to determine what to produce and to establish the priority of production based on consumption
- 30. ‘Move Card’ acts as authorization to move material from replenishment to consumption point
- 31. Number of containers used in replenishment area is determined by formula
- 32. Each container has another card attached ‘Produce Card’ – card with part no., material description and no. of cards needed to equal a signal
- 33. When taken to consumption point, container’s produce card replaced with move card
- 34. Produce card moved to Wait/ Work board Daily Demand * Replenishment Days Container Quantity= No. of Containers & Cards
- 35. Replenishment AreaConsumption AreaProduce 1 of ___Produce 1 of ___Produce 1 of ___MoveProduce 1 of ___Point of ConsumptionProduce 1 of ___
- 36. Wait/ Work BoardWorkWait51 of1 of1 of1 of1 of1 of6 7 8 9 101 of1 of11 12 13 14 15
- 37. Wait/Work Sequencing BoardOnce the predetermined no. of Produce cards are returned to the board signal is generated for the production
- 38. Provides visibility about how much has been consumed and how much more to consume before producing