The document provides an overview of the Kanban system. Some key points:
- Kanban was developed at Toyota to improve production levels through a just-in-time approach. It uses visual signals like cards to trigger replenishment actions.
- The system aims to reduce waste by producing and delivering only what is needed, when it is needed. This includes minimizing overproduction, waiting times, unnecessary transport, and defects.
- There are different types of Kanban including two-bin systems using cards or labels, and transportation vs. production Kanban. Electronic Kanban systems now integrate with ERP software.
- Implementing Kanban involves calculating demand, lead times, bin quantities, and
The document provides an overview of the Kanban system. Some key points:
- Kanban was developed at Toyota to improve production levels through a just-in-time approach. It uses visual signals like cards to trigger replenishment actions.
- The system aims to reduce waste by producing and delivering only what is needed, when it is needed. This includes minimizing overproduction, waiting times, unnecessary transport, and defects.
- There are different types of Kanban including two-bin systems using cards or labels, and transportation vs. production Kanban. Electronic Kanban systems now integrate with ERP software.
- Implementing Kanban involves calculating demand, lead times, bin quantities, and
The document provides an overview of the Kanban system. Some key points:
- Kanban was developed at Toyota to improve production levels through a just-in-time approach. It uses visual signals like cards to trigger replenishment actions.
- The system aims to reduce waste by producing and delivering only what is needed, when it is needed. This includes minimizing overproduction, waiting times, unnecessary transport, and defects.
- There are different types of Kanban including two-bin systems using cards or labels, and transportation vs. production Kanban. Electronic Kanban systems now integrate with ERP software.
- Implementing Kanban involves calculating demand, lead times, bin quantities, and
GR # 2201176 GR # 2201348 (() Kanban System Introduction Kanban was developed by Taiichi Ohno, at Toyota, to find a system to improve and maintain a high level of production. Kanban is one method through which JIT is achieved.
The word Kanban comes from Japan and its a translation from Japanese to English. Kan means card whereas ban means signal. This card signaling concept is used to prompt action. What is KANBAN System ? The Kanban method, as formulated by David J. Anderson, is an approach to incremental, evolutionary process and systems change for organizations. My laymans way of describing Kanban is that it is
A way to organize the chaos that surrounds so many delivery teams by making the need for prioritization and focus clear.
A way to uncover workflow and process problems so you may solve them in order to deliver more consistently to your client/customer/etc.
Kanbans Roots
Kanban originated in Lean manufacturing and quickly grew in popularity as knowledge workers embraced the technique to reduce costs and keep up with the ever-increasing demands of their customers. There are now thousands of companies in all types of industries using the Kanban method of continuous improvement.
Advantages of Using the Kanban System
There are many advantages to using the kanban system as a way to manage work, including:
Flexibility Focus on continuous delivery Reduction of wasted work / wasted time Increased productivity Increased efficiency Team members ability to focus
Advantages Contd Other advantages to using Kanban revolve around productivity and efficiency, two concepts that also tie back to the reduction of waste.
The Kanban system focuses on the reduction of waste in all its forms: over-production, unnecessary motion, defects, over-processing and waiting. Just-in-Time Philosophy of complete elimination of waste "Just-in-Time" means making "only what is needed, when it is needed, and in the amount needed."
For example, to efficiently produce a large number of automobiles, which can consist of around 30,000 parts, it is necessary to create a detailed production plan that includes parts procurement.
Supplying "what is needed, when it is needed, and in the amount needed" according to this production plan can eliminate waste, inconsistencies, and unreasonable requirements, resulting in improved productivity. In the TPS (Toyota Production System), a unique production control method called the "kanban system" plays an integral role.
The kanban system has also been called the "Supermarket method" because the idea behind it was borrowed from supermarkets. Such mass merchandizing stores use product control cards upon which product-related information, such as a product's name, code and storage location, are entered.
Because Toyota employed kanban signs for use in their production processes, the method came to be called the "kanban system." At Toyota, when a process refers to a preceding process to retrieve parts, it uses a kanban to communicate which parts have been used. Types of Kanban Based on Number of Bins Two Bin System Red Label Method
Based on Authorization Simple or Transportation Kanban Production or Integrated Kanban (Dual Kanban) Two Bin System
A typical application of Kanban, where the recorder card is placed at the bottom of the first bin. When this bin is empty, a third party supplier or previous workstations use the recorder card to replenish the bin.
In a two-bin system, the consumer takes his supplies from the first bin until it gets emptied. The empty bin is returned to suppliers while consumption goes on the second bin. The supplier understands the return of empty bin as a signal asking for supply. Two Bin System Two Bin System Red Label Method
The red label method consists of placing of a red label in a position to figure the order point.
The consumer supplies himself from the boxes. Once the red label is uncovered, it is returned to the supplier (order point reached). While waiting for supply, the consumer uses the remaining inventory.
Every label holds the basic information necessary for ordering: Part number Quantity to deliver Position where to put this label in the new supply Red Label Method Cont. Steps in Implementing Kanban
1. List out all the components supplied.
2. Identify the runner and stranger components based on the pull rate/day
3. Collect the average Demand/day for the last 3 months for all the components.
4. Calculate Manufacturing Lead-time for all the components. Convert it into Days.
5. Calculate logistics lead-time for all the components.
6. The Kanban quantity is to be fixed for the critical components. Steps in Implementing Kanban Cont.
7. Calculate 2 bin quantity,
Total 2 bin Qty = Pull Rate*(Mfg. Lead time+Logistic lead time)*2
8. 8) Identify the type of tray or bin to be used in the two-bin area. Bins in the 2-bin area should be different from the one used for dispatches.
9. 9) Calculate the trays/bin required for the 2-bin stock based on the container size. Using the formula
No. of tray = total bin quantity/ tray quantity. Steps in Implementing Kanban Cont.
10. Design the layout for keeping the tray.
11. Calculate the space required for keeping the bin. Mark the 2-bin area with paint.
12. Design and fabricate the stand and bin.
13. Display two-bin status board near the dispatch area.
14. Design the bin card for the components.
15. Design two-bin cardholder. This post is used to keep the card for further processing near the 2-bin area. Steps in Implementing Kanban Cont.
16. Stocking the materials in the Bins, prepare action plan for filling the bin based on the critical components in a phased manner.
17. Cleaning of Trays/Bins should be properly cleaned on a weekly basis to avoid dust and foreign particles in the components.
18. Replenishment of trays/bins should be properly done based on the pull rate on 3 month basis so that we can avoid shortage of trays/bins.
19. Damaged bin to be replaced whenever necessary.
20. Plan, Do, Check, and Act is the cycle of performance, Hence the system is to be regularly checked for the performance and update the process. Basic Kanban Rules Rule 1:Move a Kanban only when the lot it represents is consumed.
Rule 2: No withdrawal of parts without a Kanban is allowed.
Rule 3:The number of parts issued to the subsequent process must be the exact number specified by the Kanban.
Rule 4:A Kanban should always be attached to the physical parts.
Rule 5:The preceding process should always produce parts in the quantities withdrawn by the subsequent process.
Rule 6:Defective parts should never be conveyed to the subsequent process.
Rule 7:Process the Kanbans at every work center in the order in which they arrive at the work center. KanBan Evolution Many manufacturers have implemented electronic kanban systems AKA an "e-kanban system." These help to eliminate common problems such as manual entry errors and lost cards. E-kanban systems can be integrated into Enterprise Resource Planning (ERP) systems, enabling real-time demand signaling across the supply chain and improved visibility. Data pulled from e-kanban systems can be used to optimize inventory levels by better tracking supplier lead and replenishment times. Examples of Kanban Implementations Most Common Application of KanBan System