1.

Kanban for the shopfloor Productivity press (PAP)

Baker&Taylor
Table of Contents
Publisher's Message
ix
Getting Started
xi
The Purpose of This Book
xi
The Basis of This Book
xi
Two Ways to Use This Book
xii
How to Get the Most Out of Your Reading
xii
An Overview of the Contents
xiv
Introducing Key Terms and Benefits of Kanban 1 (10)
What Is Kanban?
2 (2)
The Pull System and Waste Reduction
2 (2)
What Will Make Kanban Successful?
4 (2)
Integrating Kanban with MRPII
5 (1)
Pilot or Plantwide Implementation
5 (1)
How Will Kanban Change What You Are Doing 6 (1)
Now?
What Are the Benefits of Kanban?
7 (2)
Kanban and Your Company
7 (1)
Kanban and You
8 (1)
In Conclusion
9 (2)
Summary
9 (1)
Reflections
10 (1)
The Basics of Kanban: Functions, Rules, and 11 (18)
Types of Kanban
The Differences Between Kanban and
12 (5)
Conventional Ordering Systems
Reordering Point Method and Kanban
12 (1)
Production Work Orders and Kanban
13 (1)
MRP II
14 (1)
A Summary of Push versus Pull
15 (2)
Functions of Kanban
17 (1)
To Serve as the Autonomic Nervous System 17 (1)
for Just-in-Time Production
To Improve and Strengthen the Factory
17 (1)
Rules of Kanban
18 (3)
Rule 1: Downstream Processes Withdraw
19 (1)
Items from Upstream Processes
Rule 2: Upstream Processes Produce Only 19 (1)
What Has Been Withdrawn
Rule 3: Only 100 Percent Defect-Free
19 (1)
Products Are Sent to the Next Process
Rule 4: Level Production Must Be
20 (1)
Established
Rule 5: Kanbans Always Accompany the
20 (1)
Parts Themselves
Rule 6: The Number of Kanbans Is
20 (1)
Decreased Gradually Over Time
Types of Kanban
21 (5)
Transport Kanbans
21 (2)
Production Kanbans
23 (3)
In Conclusion
26 (3)
Summary
26 (1)
Reflections
27 (2)
Phase One: Scheduling Kanban
29 (22)
How Many Kanbans Do You Need?
30 (2)
Takt Time
32 (1)
How Many Operators Are Needed?
33 (9)
Line Balancing
33 (3)
Full Work
36 (6)
Load Leveling or Smoothing-Heijunka
42 (5)
Level Production Compared to Shish-Kabob 43 (4)
Production
In Conclusion
47 (4)
Summary
47 (2)
Reflections
49 (2)
Phase Two: Circulating Kanban
51 (16)
When Do You Produce?
52 (2)

What Do You Replenish?

53 (1)
When Do You Pull?
54 (1)
Where Can You Pull From?
54 (1)
What Do You Pull?
55 (1)
What Belongs on a Kanban Card?
55 (1)
How Do You Attach Kanban Cards?
56 (1)
Steps for Circulating Kanbans
56 (8)
Rules for Circulating Kanbans
58 (1)
Rules for Transport with Kanbans
58 (1)
Supermarkets
59 (2)
Water Beetles and Milk Runs
61 (3)
In Conclusion
64 (3)
Summary
64 (1)
Reflections
65 (2)
Phase Three: Improving with Kanban
67 (22)
Fine-Tuning Production by Reducing Kanbans 68 (4)
Kanban Highlights Abnormalities
68 (1)
Reducing Kanbans Reduces Stock
69 (3)
Kanban As a Visual Control System
72 (10)
What Is the Essence of Control?
73 (1)
Five Important Steps in Creating Visual 73 (2)
Controls
Triangle Kanban
75 (4)
Other Types of Kanbans
79 (3)
Kanban and Suppliers
82 (3)
In Conclusion
85 (4)
Summary
85 (2)
Reflections
87 (2)
Reflections and Conclusions
89 (7)
A Kanban Implementation Summary
90 (2)
Reflecting on What You've Learned
92 (1)
Opportunities for Further Learning
92 (1)
Conclusions
92 (1)
Additional Resources Related to Kanban
93 (3)
Books and Videos
93 (2)
Newsletters
95
Training and Consulting
55 (40)
Website
95 (1)
About the Productivity Press Development Team 96