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next step up the ladder, or need the skills to turn your busines
The concept behind the this lean manufacturing tool is to reduce costs in high volume production
The Return on Investment from getting Certifie
lines.
In order to determine optimum system designs, research often uses simulation to determine the
Our Certification course caters for all levels of experienc
number of Kbn's and to study various aspects of pull systems, see for example [1,2].
with no time restrictions for submission of exam and
A heuristic design method has been designed by Ettl and Markus [3], which can be used to evaluate
The heuristic method provides us with a useful procedure for evaluating the impact of design
alternatives and can therefore serve as a decision support tool for managers to use when planning a
We offer 3 options tailored to your needs, from Yellow B
large-scale manufacturing system.
training and Certification, up to full Black Belt Certificati
What is Kan-ban ?
A Kan-ban is a card containing all the information required to be done on a product at each stage
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along its path to completion and which parts are needed at subsequent processes.
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A Kan-ban System consists of a set of these cards, with one being allocated
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manufactured, that travel between preceding and subsequent processes.
Kan-ban System
The Kanban System was developed (more than 20 years ago), by Mr. Taiichi Ohno, a vice president
CD - MBA V.P. of Operations Westfield IN U.S.A
of Toyota, to achieve objectives that include [4]:
o reducing costs by eliminating waste/scrap
o try to create work sites that can respond to changes quickly
o facilitate the methods of achieving and assuring quality control
o design work sites according to human dignity, mutual trust and support, and allowing workers to
reach their maximum potential.
Why Kanban?
Dramatic changes away from high product throughput and high capacity loads towards the new idea
of lower production times and work-in-progress have lead to the idea of incorporating Kan-ban
Systems in manufacturing industries (most notably in automotive industries).
These systems are most commonly used to implement the pull-type control in production systems
with aims at reducing costs by minimizing the W.I.P. inventory.
This allows an organization the ability to adapt to changes in demand, and therefore production
more quickly.
A pull-type production line is a sequence of production stages performing various process steps on
parts where each stage consists of several workstations in tandem. The flow of parts through the
overall facility is controlled by a combined push/pull control policy, which is established by the Kanbans.
A push-type policy is used for producing parts within each individual production stage.
However, parts are pulled between the production stages in accordance with the rate at which parts
are being consumed by the downstream stages.
Types of Kan-bans
The two most common types of Kan-bans used today are:
1. Withdrawal (Conveyance) Kan-ban
2. Production Kan-ban
Withdrawal (Conveyance) Kan-ban
The main function of a withdrawal Kan-ban is to pass the authorization for the movement of parts
from one stage to another.
Once it gets the parts from the preceding process and moves them to the next process, remaining
with the parts until the last part has been consumed by the next process.
The withdrawal Kanban then travels back to the preceding process to get parts thus creating the
cycle.
A withdrawal Kanban usually carries the following information:
o part number
o part name
o lot size
o routing process
o name of the next process
o location of the next process
Among the basic advantages of JIT are reduced finished goods and WIP inventory levels, shorter
product flow times, and increased worker productivity allowing for lower production costs, and
greater production customer responsiveness.
JIT objectives are met by using pull-based production planning and control systems.
The best known form of pull-control is our kan-ban control.
Kan-ban is a simple-to-operate control system, which offers the opportunity to delegate routine
material transactions on the shop floor.
A number of attractive qualities contribute to the growing popularity of kan-ban control.
Kanban is simple (mechanically) and relatively inexpensive to implement and operate.
Simply determining the quantity and location of kan-bans controls the amount of inventory.
It is a distributed control system, where complex system behaviour is controlled by simple local
rules.
Visual controls provide a direct form of communication and make clear what must be done by
managers, supervisors, and operators.
Perhaps the most attractive aspect of kanban, and the one that often makes it difficult to
implement, is its requirement for, and facilitation of, environmental improvement.
The reduction of WIP and visual control makes problems more noticeable.
This supports the saying that in order to eliminate waste, you must find it first.
The tighter coupling between processes creates a dependence, which is lacking in many push
environments and forces awareness to problems.
Despite many sources of attractiveness, kan-ban control is not without its drawbacks.
Kan-ban is often cited as being applicable only in certain environments.
Issues of kanbans appropriateness in a particular production system revolve around general
operating characteristics as well as environmental conditions.
The general operating characteristics required can be summarized as the repetitive manufacturing of
discrete units in large volumes which can be held relatively steady over a period of time.
It is stated that kan-ban is difficult, or impossible to use when there are:
(1) job orders with short production runs, or
(2) significant set-ups, or
(3) scrap loss, or
(4) large, unpredictable fluctuations in demand.
Even in spite of these problems, kanban will be the system many companies will and should use in
the near future.
Even in trying to establish an effective kan-ban, one must consider availability of relevant system
information.
References
[1] Davis W.J. and Stubitz S.J. "Configuring a Kan-Ban System Using a Discrete Optimization of
Multiple Stochastic Pesponses," int. J. Prod. Pes., 25, 721-740, 1987.
[2] Philipoon P.R. Pees L.P., Taylor, B.W. and Huang P.Y., "Dynamically Adjusting the Number of Kanban Systems in a JIT Production System Using Estimated Values of Lead Time." IEE Yrans., 199-207,
1987
[3] Spearman M.L., Woodruff D.J. and Hopp W.J., "CONWIP: A pull Alternative to Kanban, Int. J.
Prod. Res.. 28, 879-1566, 1990
[4] Singh, N. (1995) "Systems Approach to Computer-Integrated Design and Manufacturing" , John
Wiley & Sons, Inc. page 630-631.
To get a full understanding of this tool try the Kan-ban Training Pack, which includes Kanban Simulations - Simply click on the link below
Or to become certified in the use of kanban and many other Lean and Six Sigma tools, become an
accredited Lean Six Sigma Black Belt - Find out more about Lean Six Sigma Black Belt Certification