How it works Kanban - The definitive slideshow! - LeanLab

How it works the Kanban ?

The definitive slideshow to understand how it works theKanban Method

Example 1 – Point of Use / Warehouse

What you need prior to start ? (therotical aspects)

Why Use Kanban ?

Theory of Kanban

How to calculate the right number of Kanban

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What you need prior to start ?

Define the Point of Use

A place to put Kanban

The right number of Kanban

A runner/collector of Kanban

Real Example

A point of use (POU) needs balls in 6 pcs / boxes

Consumption is 18 balls / day

The runner pass every day at 10:00 am

The Lead Time to recieve from warehouse = 2 days

Safety Stock fixed at 20%

This means => 8 Kanban Cards in WIP

Monday 8:00 AM – Start Work

POU

Warehouse

Monday 8:00 AM – Start Work

POU

Warehouse

Kanban Container is Empty

Monday 8:15 AM

POU

Warehouse

Monday 8:15 AM

POU

Warehouse

First box of ballsis open for use

Monday 8:17 AM

POU

Warehouse

First box of ballsIs open for use

Kanban is located in the collection

point

Monday 9:00 AM

POU

Warehouse

Monday 10:00 AM

POU

Warehouse

Monday 10:00 AM

POU

Warehouse

The collector arrives

Monday 10:15 AM

POU

Warehouse

Bring the Kanban to the Warehouse

Monday 11:00 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Monday 11:01 AM

POU

Warehouse

1st box is finished

In Process – Recieved Monday

at 10.15 AM

Monday 11:05 AM

POU

Warehouse

2nd box is opened

Kanbanmoved

In Process – Recieved Monday

at 10.15 AM

Monday 12:00 PM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Monday 12:00 PM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Monday 14:00 PM

POU

Warehouse

2nd box is finished

In Process – Recieved Monday

at 10.15 AM

Monday 14:00 PM

POU

Warehouse

3rd box is opened

Kanban Moved

In Process – Recieved Monday

at 10.15 AM

Monday 14:15 PM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Monday 17:00 PM – End of Work

POU

Warehouse

3rd box isfinished

In Process – Recieved Monday

at 10.15 AM

Tueday 8:00 AM – Start Work

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Tuesday 8:15 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Tuesday 9:00 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Tuesday 10:00 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

The collector arrives

Tuesday 10:15 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Bring Kanban to Warehouse

Tuesday 10:30 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Tuesday 17:00 PM – End of Work

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Wednesday 8:00 AM – Start of Work

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Wednesday 8:15 AM

POU

Warehouse

In Process – Recieved Monday

at 10.15 AM

Wednesday 8:30 AM

POU

Warehouse

Stick Kanban on the box

Wednesday 8:45 AM

POU

Warehouse

In Process – Recieved

Tuesday at 10.15 AM

Wednesday 9:30 AM

POU

Warehouse

In Process – Recieved

Tuesday at 10.15 AM

Wednesday 10:00 AM

POU

Warehouse

In Process – Recieved

Tuesday at 10.15 AM

The collector arrives

Wednesday 10:15 AM

POU

Warehouse

In Process – Recieved

Tuesday at 10.15 AM

Bring Kanban to the Warehouse

Wednesday 17:00 PM – End of Work

POU

Warehouse

In Process – Recieved

Tuesday at 10.15 AM

Empty in the POU – a warning to

warehouse is given

Wednesday 17:00 PM – End of Work

POU

Warehouse

In Process – Recieved

Tuesday at 10.15 AM

EMPTY is always a Visual Warning

Thursday 8:00 AM – Start of Work

POU

Warehouse

Because of warning the material in in POU

at 8:00 AM

Thursday 8:15 AM

POU

Warehouse

Thursday 8:30 AM

POU

Warehouse

Thursday 10:00 AM

POU

Warehouse

The collector arrives

Thursday 17:00 PM – End of Work

POU

Warehouse

Friday 8:00 AM – Start of Work

POU

Warehouse

Friday 17:00 PM – End of Work

POU

Warehouse

Next Week the same cycle ...

Some Considerations

The WIP is under control (48 balls in 8 boxes)

Is the system too risky of stock-out in the POU and why? Looking carefully at the lead time, if the collector comes at 10.00 AM, the POU start at 8.00 AM and the warehouse brings the boxes at 9.00 AM the lead time to consider is not 2 days but 2 days and 3 hours.

In this case the correct lead time to use is round 2.5 days and the kanban system need is:

9 Kanban Cards rather than 8 Kanban Cards

Some Considerations

At the beginning of Kanban Implemetation starts with a safe number of kanban cards and then reduced it when the system will be stable and reliable.

Thank you for your attention

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