Kanban Book Final

1Kanban A New Approach(Tool for Information Flow)

2Agenda

Topic/Activity

Opening

Introduction

Information Flow

Break

Kanban Simulation1

Break

The Customer

Leveling Exercise

Lunch

Kanban Simulation 2

Internal Pull System

Break

Lot Box Production

Lot Size Calculation

Break

Material Movement

Supplier Card Calculation

Closing

3Kanban System

Based on Toyota Production System

Driven by External Customers

Addresses Constraints & Bottlenecks

1. Understanding our Capabilities

2. Lot Size Production

4Overview

Supporting Company Strategy

Understanding Customer Needs

Internal Kanban System

Signaling the Supplier

5The Objective

Create Information System that Supports Lean Principles

Pull of Product Based on Usage

Lower Inventory / Reduced Lead-Time

6Company Strategy

Grow our Business

Internal and external

Strengthen our resources

Improve our Competitive Position

Continually strive for perfection

Reduce cost

Eliminate waste in operations

7Supporting Company Strategy

Elimination of Waste

Overproduction

Material movement

Inventory

Transition to Just-in-Time

Kanban system

Kanban signals

8 Production schedules will always change

Production will never go according to schedule

It is human nature to overproduce

Key Assumptions

9Offsetting the Assumptions

Kanban System

Withdraw only what you need

Replenish what is taken

Overall Benefits

Flexibility in production

Prevents overproduction

Reduces inventory

10

Information Flow

11

The Kanban Signal

The Kanban signal tells us:

When to make it! When to move it!

12

Kanban System

Supplying

Process

Customer

Process

product

Production Card

Finished Goods

Store

Withdrawal Card

product

13

Withdrawal Kanban Signal

Tells us:

When to move

What to move

Where to move

How much to move

14

Three Types of Withdrawal Kanban Signals

Customer Kanban Signal

Transfers material from plant to customer

Move Kanban Signal

Transfers material between work units

Supplier Kanban Signal

Pulls material from supplier to plant

15

Customer Kanban Signal Information

Supplier

Quantity

Supplier Number

Card Number

Kanban Signal Number

Container Type

Part Number

Description

Storage Location

Storage Address

16


Supplier

Kanban

Signal No.

Part No.

Storage Location

Quantity Supplier

No.

Card No.

Container

TypeDescription

Storage Address

17

Flow of Customer Kanban Signal

Plant

Finished

Goods

Store

External

Customerneeded product


18

Move Kanban Signal Information

Part Number

Supplier Name

Storage Address (Point of Storage)

Card Number


Work Unit Name (Customer)

Quantity per Container

Line Address (Point of Use)

19

Move Kanban Signal

WORK UNIT ADDRESSSTORE ADDRESS

SUPPLIER NAME Kanban Signal No. WORK UNIT NAME

PART No. QUANTITY CARD #

20

Flow of Move Kanban Signal

Internal

Raw

Material

Store

Production

Work Unitneeded product

Move Kanban Signal

21

Supplier Kanban Signal Information

Supplier Name

Part Number

Part Name

Customer

Storage Address

Work Unit Address


Card Number


22


Kanban Signal NumberSupplier Name

Part Number Quantity Card No.

Customer

Store Address Work Unit

Address

Part Name

23

Flow of Supplier Kanban Signal

External

Supplier

Finished

Goods

Store

needed product


Internal

Raw

Material

Store

24

External

Supplier

Internal

Raw

Materials

Storeneededproduct

Flow of Withdrawal Kanban Signals

Internal

Production

Work

Unitneededproduct

Plant

Finished

Goods

Storeneededproduct

External

Customer

needed

product

Supplier Signal Move Signal Customer Signal

25

Production Kanban Signal

Tells Us:

When to make

What to make

How much to make

26

Two Types of Production Kanban Signals


Instructs us to make One Container

Signal (Triangle)

Instructs us to produce One Lot

Used when a work unit does not have the changeover capability to produce one container for one production card

27

Production Card Information

Store Address


Work Unit Name

Part Number

Quantity

Card Number

28

Production Card

STORE ADDRESS

Kanban

Signal No.WORK UNIT NAME


29

Signal (Triangle) Information

Work Unit Name

Part Number

Container Type

Quantity

Process Time

Lot Size

Order Point


30

Signal (Triangle)

WORK UNIT

NAME

PART No.

CONTAINER

TYPE

QUANTITY PROCESSINGTIME FOR 1 LOT

LOT SIZE ORDER POINT

Kanban Signal #

# of containers to produce

Where the signal

is placed in inventory

31

Flow of Production Kanban Signals

Internal

Sub

Assembly

Work

Unit

Store

Internal

Final

Assembly

Work

Unitneededproduct

Finished

Goods

Store

needed

product

Internal

Sub

Assembly

Work

Unitneeded

product

Triangle SignalProduction Signal Move Signal

32

Kanban Signal Flow

Sub

Assembly

Work Unit

Finished

Assembly

Work Unit


Triangle

Kanban Signal

Move

Sub Stores

Finished Goods

Store

A CB D

33

How Do You Handle Non-Standard Situations

Temporary Kanban Signals

Need scheduled down time to PM equipment

Sample parts

Service parts

34

Temporary Kanban Signal Card

STORE

ADDRESS

WORK UNIT NAME


Kanban

Signal No.

35

Summary of Kanban Types

Withdrawal

- Customer Kanban Signal

- Move Kanban Signal

- Supplier Kanban Signal

Production

- Production Kanban Signal

- Signal (Triangle)

- Temporary Kanban Signal

36

Additional Benefits of Kanban

Support Visual Control

Are we behind?

What do I produce first?

What is my inventory situation?

Continuous Improvement

Large inventories hide problems

Facilitate continuous improvement by removing Kanban Signals

37

Kanban System Simulation

Exercise 1

(Without Leveling)

38

Kanban System Simulation - Exercise 1

Objective

To gain an understanding of Kanban System card transfer, exchange, and loop location

39


Details

Activity will be run in time segments

Each time segment consists of one day

One truck from customer per day

Simulation will run for 5 days

40

Kanban System Simulation - Exercise 1 Activity Pieces

35 Plastic bowls

73 White Lego Blocks

35 Yellow Lego Blocks

5 Customer Cards

18 Place Mats

13 Production Cards

8 Move Cards

4 Supplier Cards

5 Signal Posts

5 Order Cards

41

Activity Layout - Exercise 1

W

YCustomer

Empty

Containers

Signal

Post

4

Final

Assembly

3

3

3

Empty

Containers

Signal

Post

1@15

3

3

3

Sub

Assembly

1

1

1

Empty

Containers

Signal

Post

2@15

1Raw

Material

Processing

Empty

Containers

Signal

Post

1

Supplier

Empty

Containers

Signal

Post

A B C

D

E F G H I

J

A - Customer

B - Truck Driver-1 (Customer to Plant)

C - Final Assembly Operator

D - Material Handler-1 (Final Assembly to Sub-Assembly)

E - Sub-Assembly Operator

F - Material Handler-2 (Sub-Assembly to Raw Material Storage)

G - Raw Material Processing (Parts Ordering / Parts Receiving)

H - Truck Driver-2 (Plant to Supplier)

I - Supplier

J - ManagerW W

Y4 =

W

Y3 =

Y2 =

W1 =

1@15

4

44

44 4

44

4

11

1

11

1

3 3 1

42

Activity Layout - Exercise 1Card Types

W

Y

Empty

Containers

Customer

4

4

4

4

4

Signal

Post

4

4

4

4

4

Final

Assembly

3

3

3

Empty

Containers

Signal

Post

3

3

3

Sub

Assembly

1

1

1

Empty

Containers

Signal

Post

1

1

1Raw

Material

Storage

Empty

Containers

Signal

Post

1

1

1

Supplier

Empty

Containers

Signal

Post

Customer Card

Production Card

Move Card

Production Card

Move Card

Supplier Card Production Card

1 1

3 3 1

43

Kanban System Simulation - Exercise 1 Roles

Customer

Receive order from facilitator

Move raw materials to customer processing area

Remove Customer Cards from container

Place Customer Cards in Signal post

Disassemble lego blocks and place in designated containers

Move empty containers to customer empty container storage

Repeat above steps for each order

44

Truck Driver 1

Pick up Cards from Signal post

Pick up empty containers from customer empty container storage

Move empty containers to finished goods empty container storage

Remove Production Cards from finished goods container and replace with Customer Cards

Place Production Cards in final assembly Signal post

Move finished goods to customer raw material storage

Repeat above steps for each daily order


45

Final Assembly Operator

Check final assembly Signal post for production requirements

Move raw material container to final assembly processing area

Remove sub-assembly and place on final assembly processing area

Remove Move Card and place in empty container

Move empty container back to final assembly raw materials storage

Pick up empty container from finished goods empty container storage and move to final assembly processing area

Pick up white processing lego and assemble to sub-assembly and place in finished goods container

Pick up Production Card from Signal post and place on finished goods container

Move finished goods container to final assembly finished goods storage

Repeat above steps for each Kanban Signal


46

Material Handler 1

Pick up Move Cards and empty containers from final assembly raw material storage

Place empty containers in sub-assembly empty container storage

Remove Production Cards from sub-assembly finished goods and replace with Move Cards

Place Production Cards in the sub-assembly Signal post

Move finished goods containers to final assembly raw material storage



47

Sub-Assembly Operator

Check sub-assembly Signal post for production requirements

Move raw material container to sub-assembly processing area

Remove raw material and place on sub-assembly processing area

Remove Move Card and place in empty container

Move empty container back to sub-assembly raw material storage

Pick up empty container from sub-assembly empty container storage and move to sub-assembly processing area

Pick up yellow processing lego and assemble to raw material and place in finished goods container

Pick up Production Card from Signal post and place on finished goods container

Move finished goods container to sub-assembly finished goods storage



48

Material Handler 2

Pick up Move Cards and empty containers from sub-assembly raw material storage

Place empty containers in raw material empty container storage

Remove Supplier Cards from raw material storage and replace with Move Cards

Place Supplier Cards in the raw material Signal post

Move raw material containers to sub-assembly raw material storage



49

Raw Material Store (Parts Ordering)

Move empty container from raw material empty container storage to raw material processing

Remove Supplier Card from supplier Signal post

Place Supplier Card on empty container


Prepare order for shipment

Raw Material Store (Parts Receiving)

Move raw material container from raw material receiving to raw material storage area


50

Truck Driver 2

Pick up empty containers with Supplier Cards from raw material processing area

Place empty containers in Suppliers empty container storage

Remove Supplier Production Cards from suppliers raw material container and replace with Supplier Cards

Place Supplier Production Cards in supplier Signal post

Move raw materials from supplier to raw material receiving



51

Supplier

Check Supplier Signal post for production requirements

Move empty container from supplier empty container storage to supplier processing area

Pick up white processing lego and place in raw material container

Pick up Production Card from supplier Signal post and place on raw material container

Move raw material container to supplier finished goods storage



52

Manager

Review the daily production requirements

Instruct cells to produce to customer demand or capacity

Monitor the production of parts in the value stream

Evaluate daily production results


53

Kanban System Simulation - Exercise 1Customer Orders vs Capacity

3 units = 8hrs 00min


Capacity

1 unit = 2hrs 40min


Day Customer Capacity Actual Production

Order Production Hours

1

2

3

4

5

54

The Customer

(Starting Point for a Kanban System)

55

Understanding Customer Needs

Customer Demand

Anticipated Requirements (Forecast)

Takt Time (time required to produce a single part based upon customer usage)

Actual Requirements (Daily Pull)

Leveling

56

Anticipated Requirements

What information do we need?

Customer demand for the month

Number of days in demand period

Part Monthly Demand No. of Working Days Daily Demand

A 18,000 20 900

Note: 900 units / 2 shifts = 450 units per shift

57

Takt Time

Available Operating Time

PiecesTakt Time =

57,600 - 2,400

900 pcs=

61.33 per piece=

Sets pace of production to match customer

demand

58

Production

Work UnitCustomer

Producing to Customer Demand

Customer CardProduction Card

59

Customer Ordering History

0

200

400

600

800

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Day

Un

its

0

200

400

600

800

1000

1200

1400

1600

Forecast

Actual

60

Analyze Actual Requirements

Anticipated Demand vs. Actual Demand

Part Anticipated Demand Actual Demand Difference

A 18,000 19,000 1000

61

Opportunities in Customer Fluctuation

Buffer Stock

Used when demand is in excess of customer forecast

Replenished when demand is less than customer forecast

Note: Buffers are an indicator of waste in the system!

62

Leveled Production

(Based On 500 Units Of Buffer Stock)

0

200

400

600

800

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Day

Un

its

0

200

400

600

800

1000

1200

1400

1600

Forecast

Actual

Production

63

Opportunities in Truck Pitch

Even Truck Pitch

Drives constant Takt Time

Reduces fluctuation

Overall Benefit

Reduction in inventory

64

Truck Pitch

Truck 2 Truck 3 Truck 4 Truck 1

6:00 10:00 14:30 16:00 21:00 24:30

= Break

= Lunch

= Between

Shifts

Truck Times

1 - 6:00 3 16:00

2 - 10:00 4 21:00

65

Replenishment Capability

Truck Pick-up Times

1. 6:00 2. 10:00 3. 16:00 4. 21:00

Replenishment Capability Based on Takt Time

21:00 - 24:30 = 3.5 hours = 12,600 seconds

12,600 seconds - 600 seconds (break) = 12,000 seconds

12,000 seconds / 61.33 seconds (takt time) = 195.66 pcs

195.66 pcs / 50 pcs in container = 3.91 containers

Truck 1 = 3 containers (45.66 remaining for Truck 2)

66

Leveling Post

1 2 3 4 Buffer Stock

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

500 pcs. used to buffer Customer Orders

50 pcs. per container

10 slots required in Leveling Post for Buffer

67

Production

Work UnitCustomer

Leveling

Post

B

P

Leveling Customer Demand

Forecast

68

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

Takt Time Post

69

Information Required for Takt Time Post

Takt Time = 61.33 seconds

Number of pieces per container = 50

Time per container = (Takt Time * Container Quantity) / 60

= (61.33 * 50) / 60 = 51 minutes(Must deliver a Kanban from the Takt Time Post

to the Production Work Unit every 51 minutes)

70

Takt Time Post

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

71

Production

Work UnitCustomer

Leveling

Post

B

P

Leveling Customer Demand

Forecast

Takt Time

Post

72

Separating Safety Stock

Distinguish between customer fluctuation and internal problems

Safety Stock inventory amount is based on downtime history

73

Production

Work UnitCustomer

Leveling

Post

B

P

Utilizing Safety Stock

Forecast

Takt Time

Post

S

74

Leveling

Benefits:

Neutralizes fluctuation from:

Customers orders

Truck pitch

Pulls product based on:

Customer usage

Takt Time

75

Leveling System

Visual Aid 1

(Neutralizing Customer Fluctuation)

76

Objective

To establish a pull system of production that levels the demand of the customer to meet production capabilities

77

Visual Aid Requirements

Leveling Post

Takt Time Post

Signal Post

(20) Customer Cards

(7) Production Cards

(10) Buffer Stock Cards

(5) Safety Stock Cards

78

Card Number

To determine the number of Production Cards in the system, take the highest available Cards to be shipped on one truck and add one Card.

EXAMPLE:

Truck 4 = 6 Cards

6 Cards + 1 Card = 7 Cards

(7) Production Cards Required

Note: Additional Cards may be required for longer lead-times

79

Card Placement

To determine the location of the Production Card on the takt time post, take the available Cards for the last truck and subtract the

quantity for the first truck and count backwards from the last truck

EXAMPLE:

Truck 4 - Truck 1 = Cards Generated for 1st

(6) - (3) = 3 Cards for 1st Shift

Note: If the number is zero or a negative number, only the last Card of the last truck is generated for 1st shift

80

Visual Aid Layout - Day 1 (End of 2nd Shift)

Leveling Post

Takt Time Post

6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

81

Visual Aid Layout - Day 2 (6:00 am)

Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T

82

Visual Aid Layout - Day 2 (6:00 am - continued)

Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

9

3

0

2

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

1

0

1

8

1

0

2

4

3

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

1

1

3

0

1

1

3

6

1

1

4

2

L

/

T

4

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

5

1

2

4

2

1

2

4

8

1

2

5

4

L

/

T

L

/

T

L

/

T

L

/

T

83

Visual Aid Layout - Day 2 (10:00 am)Leveling Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

Takt Time Post9

3

0

2

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

1

0

1

8

1

0

2

4

3

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

1

1

3

0

1

1

3

6

1

1

4

2

L

/

T

4

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

5

1

2

4

2

1

2

4

8

1

2

5

4

L

/

T

L

/

T

L

/

T

L

/

T

B

/

T

B

/

T

84


Leveling Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

Takt Time Post1

0

0

1

0

6

1

1

2

1

1

8

1

2

4

1

3

0

1

3

6

6

1

4

2

1

4

8

1

5

4

2

0

0

2

0

6

2

1

2

2

1

8

2

2

4

2

3

0

2

3

6

2

4

2

2

4

8

2

5

4

3

0

0

3

0

6

3

1

2

3

1

8

3

2

4

3

3

0

3

3

6

3

4

2

3

4

8

3

5

4

4

0

0

4

0

6

4

1

2

4

1

8

4

2

4

B

/

T

B

/

T

85


Leveling Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

Takt Time Post4

3

0

7

4

3

6

4

4

2

4

4

8

4

5

4

5

0

0

5

0

6

5

1

2

5

1

8

8

5

2

4

5

3

0

5

3

6

5

4

2

5

4

8

5

5

4

6

0

0

6

0

6

6

1

2

9

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

7

0

0

7

0

6

7

1

2

10

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

7

4

8

7

5

4

B

/

T

B

/

T

86

Visual Aid Layout - Day 2 (4:00 pm)

Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

4

3

0

7

4

3

6

4

4

2

4

4

8

4

5

4

5

0

0

5

0

6

5

1

2

5

1

8

8

5

2

4

5

3

0

5

3

6

5

4

2

5

4

8

5

5

4

6

0

0

6

0

6

6

1

2

9

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

7

0

0

7

0

6

7

1

2

10

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

7

4

8

7

5

4

B

/

T

B

/

T

87

Visual Aid Layout - Day 2 (4:00 pm - continued)

Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

8

0

0

11

8

0

6

8

1

2

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

8

4

8

8

5

4

12

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

9

3

0

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

13

1

0

1

8

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

14

1

1

1

2

1

1

1

8

1

1

2

4

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

B

/

T

B

/

T

88


Leveling Post

Takt Time Post8

0

0

11

8

0

6

8

1

2

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

8

4

8

8

5

4

12

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

9

3

0

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

13

1

0

1

8

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

14

1

1

1

2

1

1

1

8

1

1

2

4

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

B

/

T

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

89


Leveling Post

Takt Time Post1

1

3

0

1

1

3

6

1

1

4

2

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

15

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

1

2

4

2

1

2

4

8

1

2

5

4

1

0

0

1

0

6

1

1

2

1

1

8

1

2

4

1

3

0

1

3

6

1

4

2

1

4

8

1

5

4

2

0

0

2

0

6

2

1

2

2

1

8

2

2

4

2

3

0

2

3

6

2

4

2

2

4

8

2

5

4

B

/

T

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

90


Leveling Post

Takt Time Post6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

91


Leveling Post

Takt Time Post6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

92

Visual Aid Layout - Day 2 (End of 2nd Shift - cont.d)

Leveling Post

Takt Time Post6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

93


Leveling Post

Takt Time Post6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

94


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

9

3

0

2

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

1

0

1

8

1

0

2

4

3

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

1

1

3

0

1

1

3

6

1

1

4

2

L

/

T

4

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

5

1

2

4

2

1

2

4

8

1

2

5

4

L

/

T

L

/

T

L

/

T

L

/

T

95


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

9

3

0

2

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

1

0

1

8

1

0

2

4

3

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

1

1

3

0

1

1

3

6

1

1

4

2

L

/

T

4

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

5

1

2

4

2

1

2

4

8

1

2

5

4

L

/

T

L

/

T

L

/

T

L

/

T

B

/

T

B

/

T

96


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

1

0

0

1

0

6

1

1

2

1

1

8

1

2

4

1

3

0

1

3

6

6

1

4

2

1

4

8

1

5

4

2

0

0

2

0

6

2

1

2

2

1

8

2

2

4

2

3

0

2

3

6

2

4

2

2

4

8

2

5

4

3

0

0

3

0

6

3

1

2

3

1

8

3

2

4

3

3

0

3

3

6

3

4

2

3

4

8

3

5

4

4

0

0

4

0

6

4

1

2

4

1

8

4

2

4

B

/

T

B

/

T

97


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

4

3

0

7

4

3

6

4

4

2

4

4

8

4

5

4

5

0

0

5

0

6

5

1

2

5

1

8

8

5

2

4

5

3

0

5

3

6

5

4

2

5

4

8

5

5

4

6

0

0

6

0

6

6

1

2

9

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

7

0

0

7

0

6

7

1

2

10

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

7

4

8

7

5

4

B

/

T

B

/

T

98


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

4

3

0

7

4

3

6

4

4

2

4

4

8

4

5

4

5

0

0

5

0

6

5

1

2

5

1

8

8

5

2

4

5

3

0

5

3

6

5

4

2

5

4

8

5

5

4

6

0

0

6

0

6

6

1

2

9

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

7

0

0

7

0

6

7

1

2

10

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

7

4

8

7

5

4

B

/

T

B

/

T

99


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

8

0

0

11

8

0

6

8

1

2

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

8

4

8

8

5

4

12

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

9

3

0

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

13

1

0

1

8

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

14

1

1

1

2

1

1

1

8

1

1

2

4

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

B

/

T

B

/

T

100


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

8

0

0

11

8

0

6

8

1

2

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

8

4

8

8

5

4

12

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

9

3

0

9

3

6

9

4

2

9

4

8

9

5

4

1

0

0

0

1

0

0

6

1

0

1

2

13

1

0

1

8

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

14

1

1

1

2

1

1

1

8

1

1

2

4

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

B

/

T

B

/

T

101


Leveling Post

Takt Time Post


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

1

1

3

0

1

1

3

6

1

1

4

2

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

15

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

1

2

4

2

1

2

4

8

1

2

5

4

1

0

0

1

0

6

1

1

2

1

1

8

1

2

4

1

3

0

1

3

6

1

4

2

1

4

8

1

5

4

2

0

0

2

0

6

2

1

2

2

1

8

2

2

4

2

3

0

2

3

6

2

4

2

2

4

8

2

5

4

B

/

T

B

/

T

102


Leveling Post

Takt Time Post6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

103


Leveling Post

Takt Time Post6

0

0

16

6

0

6

6

1

2

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

17

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

7

3

0

7

3

6

7

4

2

18

7

4

8

7

5

4

8

0

0

8

0

6

8

1

2

B

/

T

8

1

8

8

2

4

8

3

0

8

3

6

8

4

2

1

8

4

8

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

B

/

T


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

104

Kanban System Simulation

Exercise 2

(With Leveling)

105


Objective

To gain an understanding of the method and benefits of leveling

106


Details

Activity will be run in time segments

Each time segment consists of one day

One truck from customer per day

Simulation will run for 5 days

Leveling of production occurs at the Point of Pull

107

Kanban System Simulation - Exercise 2Activity Pieces

36 Plastic bowls

75 White Lego Blocks

36 Yellow Lego Blocks

5 Customer Cards

11 Production Cards

18 Place Mats

3 Buffer Stock Cards

8 Move Cards

4 Supplier Cards

5 Signal Posts

1 Leveling Post

5 Order Cards

108

Activity Layout - Exercise 2

W

YCustomer

4

4

4

4

4

Empty

Containers

Signal

Post

4

4

4 4

4

4

Final

Assembly

3

3

3

Empty

Containers

Signal

Post

1@15

3

3

3

Sub

Assembly

1

1

1

Empty

Containers

Signal

Post

2@15

1

11Raw

Material

Storage

Empty

Containers

Signal

Post

1

11 Supplier

Empty

Containers

Signal

Post

A B C

D

E F G H I

J

A - Customer

B - Truck Driver-1 (Customer to Plant)

C - Final Assembly Operator

D - Material Handler-1 (Final Assembly to Sub-Assembly)

E - Sub-Assembly Operator

F - Material Handler-2 (Sub-Assembly to Raw Material Storage)

G - Raw Material Processing (Parts Ordering / Parts Receiving)

H - Truck Driver-2 (Plant to Supplier)

I - Supplier

J - ManagerW W

Y4 =

W

Y3 =

Y2 =

W1 =

1@15Leveling

Post

1 1

3 13

109

Activity Layout - Exercise 2Card Types

Customer Cards

(3) Production Cards

(3) Buffer Stock Cards

Move Cards

Production Cards

Move Cards

Supplier Cards Production Cards

W

Y

Empty

Containers

Customer

4

4

4

4

4

Signal

Post

4

4

4 4

4

4

Final

Assembly

3

3

3

Empty

Containers

Signal

Post

3

3

3

Sub

Assembly

1

1

1

Empty

Containers

Signal

Post

1

1

1Raw

Material

Storage

Empty

Containers

Signal

Post

1

1

1

Supplier

Empty

Containers

Signal

Post

Leveling

Post

1 1

3 3 1

110

Kanban System Simulation - Exercise 2Roles

Following Roles Same As Exercise 1

Customer

Final Assembly Operator

Material Handler 1

Sub-Assembly Operator

Material Handler 2

Raw Material Store

Truck Driver 2

Supplier

111


Truck Driver 1

Pick up Customer Cards from Customer Signal post

Pick up empty containers from customer empty container storage

Move empty containers to finished goods empty container storage

Place Customer Cards in leveling post

Remove Cards from leveling post after leveling

Remove Production Cards from finished goods container and replace with Customer Cards

Place Production Cards, and/or Buffer Stock Cards if required, in final assembly Signal post

Move finished goods to customer raw material storage


112


Manager

Focus on improving operations

113

Kanban System Simulation - Exercise 2Customer Orders vs Capacity

Day Customer Capacity Actual Production

Order Production Hours

1

2

3

4

5



Capacity

1 unit = 2hrs 40min


114


(Operating The Internal System)

115


Production Instruction

Production Card

Signal (Triangle)

Material Movement

Move Card

Delivery system

116

Kanban SignalTool To Trigger Production

Production Card

High level of capability in the work unit

Production of parts in any order

117

If a work unit can produce parts in the same order that they are pulled from stores, then they produce Card for Card

The Production Card (typically a white card) is attached to the container after production

When a container is pulled from the work unit store, the card is removed and sent back to the work unit to trigger production

ProducingCard for Card

118

The Production Card is the signal to produce a container of a particular part number

The work unit produces in the order that the Production Cards are received

Changeover time must be equal to or less than the consumers changeover time

Points to Remember

119

Flow of the Production Card

Supplying

Process

product

Production Card

120

Kanban SignalTool to Trigger Production

Signal (Triangle)

Long changeover times

Production in lot size

121

Production by Lot Size

A B CC CA A B

1st 2nd

CB

3rd 4th

Withdrawal Period

A B

Direct Relationship between Changeover times and Inventory Levels

122

Signal (Triangle)

WORK

UNIT

NAME

PART No.

CONTAINER

TYPE

QUANTITY PROCESSINGTIME FOR 1 LOT

LOT SIZE ORDER POINT

Signal #

# of containers to produce

Where the signal

is placed in inventory

123

Signal Triangle

When using the Signal Triangle, every part number on the work unit has its own signal

The signal instructs the work unit to produce and is dependent on how inventory is pulled from the work unit

If parts are not withdrawn from the work unit, the work unit will not receive a signal to produce

124

Lot Size Production

Signal Instructs the Work Unit:

When to produce the part

How many to produce at one time

125

Elements Required to Determine the Lot Size

Available Time

Monthly Demand for Each Part Number

Production Time for Each Part Number

Average Changeover Time

126

Available Time

Available Time =

(Number of Hours per Shift) (Break Time)

57,600 seconds - 2,400 seconds = 55,200 seconds

Number of Shifts: 2 Hours per Shift: 8

Number of Breaks per Shift: 2 Minutes per Break: 10

127

Demand Calculation

Daily Demand = Monthly Demand

# of Days in Demand Period

Part Monthly Demand Daily Demand

A 4000 pcs 200 pcs

B 6000 pcs 300 pcs

C 8000 pcs 400 pcs

D 12000 pcs 600 pcs

Total 30000 pcs ???? pcs

Days in Month = 20

128

Demand Calculation

Daily Demand = Monthly Demand

# of Days in Demand Period

Part Monthly Demand Daily Demand

A 4000 pcs 200 pcs

B 6000 pcs 300 pcs

C 8000 pcs 400 pcs

D 12000 pcs 600 pcs

Total 30000 pcs 1500 pcs

Days in Month = 20

129

Calculating Production Time

Production Time = Cycle Time x Daily Demand

Part Daily Demand Cycle Time Production Time

A 200 28.5 5700

B 300 28.0 8400

C 400 30.5 12200

D 600 32.0 19200

Total 1500 30.3 ??????

130

Calculating Production Time

Production Time = Cycle Time x Daily Demand

Part Daily Demand Cycle Time Production Time

A 200 28.5 5700

B 300 28.0 8400

C 400 30.5 12200

D 600 32.0 19200

Total 1500 30.3 45500

131

Calculating Average Changeover Time

Part Daily Demand Changeover Time

A 200 900 seconds

B 300 600 seconds

C 400 720 seconds

D 600 600 seconds

Total ???? ???? seconds

Average C/O Time = Changeover Time = ???? = ???

# of Parts Numbers ?

Total

132

Calculating Average Changeover Time

Part Daily Demand Changeover Time

A 200 900 seconds

B 300 600 seconds

C 400 720 seconds

D 600 600 seconds

Total 1500 2820 seconds

Average C/O Time = Changeover Time = 2820 = 705

# of Parts Numbers 4

Total

133


Step 1: Determine the Number of Changeovers per Day

# of C/O per Day = Available Time - Production Time


# of C/O per Day = ????? - ????? = ??? C/Os

???

(# of Parts) (# of Available C/Os)

(?)

/

/ (???)

= (LOT SIZE)

= ??? Days

134


Step 1: Determine the Number of Changeovers per Day

# of C/O per Day = Available Time - Production Time


# of C/O per Day = 55,200 - 45,500 = 13.7 C/Os

705

(# of Parts) (# of Available C/Os)

(4)

/

/ (13.7)

= (LOT SIZE)

= .29 Days

135

Lot Size per Part Number

Part Daily Demand Lot Size # in Lot

A 200 0.29 days 58 pcs

B 300 0.29 days 87 pcs

C 400 0.29 days 116 pcs

D 600 0.29 days 174 pcs

136

# of Containers in a Lot = Lot Size

Qty per Cont.

Example:

Lot Size for Part A = 58 pcs

Container Size = 30 pcs

Part A = 58 pcs per lot size = 1.9 containers

30 pcs per container

Part A Lot Size = 2 ContainersRound Up

to Next Full

Container

Container Lot Size

137

Order Point

The order point determines how much inventory is needed in the stores to cover customer requirements during the

work units peak period of downtime

For instance, the order point = 2

The signal is placed on the 2nd to the last container. When the container above the signal on is pulled, exposing the

Signal Triangle, the signal goes back to the line to trigger

production with the corresponding amount of Production

Cards

138

Signal (Triangle)

Pull

from Top

Remove Signal Triangle

when this container is

pulled!!

139

Order Point Calculation(Daily Demand x Downtime Percentage) = Order Point


Daily Demand: 200pcs (200 x .20) = 1.33

Peak Downtime Percentage: 20% 30

Quantity per Container: 30pcs

Order Point: 2 Round Up

to Next Full

Container

140

Order Points

Part Daily Demand D/T #PCS Pcs/Cont O.P.

A 200 .20 40 30 ?

B 300 .20 60 30 ?

C 400 .20 80 30 ?

D 600 .20 120 30 ?

141

Order Points

Part Daily Demand D/T #PCS Pcs/Cont O.P.

A 200 .20 40 30 2

B 300 .20 60 30 2

C 400 .20 80 30 3

D 600 .20 120 30 4

142

How are the Containers Identified?

A Production Card is placed on a container after it is produced

When the container is pulled from the store the Production Card is removed and is put into a collection

box, while a Move Card is put on the container in its place

When the signal is sent to the work unit for production, the number of Production Cards that are needed to I.D.

the containers are also taken

143

1.

Inventory Stores

3.

2.

Inventory Stores

Inventory Stores

The Production Card is put

into a collection box to be

sent back to the work unit.

Move Card signals that

the Customer Work Unit

needs parts.

The container is picked

and the Kanban Card is

replaced with the Move

Card.

Parts are taken to the

Customer Work Unit.

144

# of Production Cards in the System

# of Production Cards = Lot Size + Order Point

= 2 + 2

= 4 Tags

The number of cards is the maximum amount of

material that will be in the stores

145

Flow Of The Signal ( Triangle)

Order

Point

Customer

Pulling

Now Next

Roll Cut Work Unit

Signal Board

A B C D

Roll Cut Stores

A

B

C

D

A B DC

Collection

Box

146

Lot Box Production

An Alternative Approach for Increased

Visual Management

147

Supplying

Process

product

Production Card

Lot Box Production Flow

Lot

Box

148

The Lot Box

Order PointProduction Cards

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Zero Inventory

149

Work Unit Kanban Post

Part D C/O Card Part A C/O Card

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

A B C D E F G H I

Daily Demand Lot S ize Cycle T ime C/O Lot T ime T otal Run Container S ize M in. / Container C.O. T ime (min.) Calculations

E=(BXC)

F=(D+E)

H=(GXC)/60

I=D/60

Part #

1 2 3 4 5 6 C/O Total

A

B

C

D

Container No.

151

Example for Part # C

A: I - I - -

B: I - I - - I - -

C: I - I - - I - I - -

D: I - - I - - I - I - - I - I - -

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

1 2 3 4 5 6 C/O TOTAL15.25 30.5 45.75 61 X X 12 73

152

Lot Box Production

Visual Aid 2

(An Alternative Approach)

153

Objective

To visually demonstrate the flow of Cards based on lot size production using the Lot Box as a tool for instruction

to produce.

154

Visual Aid Requirements

1 Lot Box

1 Kanban Post

1 Parts Withdrawal Timing Sheet

4 (Part A) Production Cards

5 (Part B) Production Cards

7 (Part C) Production Cards

10 (Part D) Production Cards

17 Changeover Cards

155

Visual Aid Layout

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

Kanban Post

156

Visual Aid Layout Inventory Status

Part A Part B Part C Part D

1 Container 1 Container 1 Container 1 Container

1 Container 1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

157

Part Withdrawal Timing

Part A

8:10 am

10:38 am

1:36 pm

5:54 pm

8:22 pm

11:10 pm

Part B

7:32 am

9:14 am

10:46 am

12:48 pm

2:30 pm

6:02 pm

7:44 pm

9:16 pm

11:18 pm

1:00 am

Part C

7:09 am

8:18 am

9:37 am

10:46 am

12:25 pm

1:44 pm

4:53 pm

6:02 pm

7:21 pm

8:30 pm

10:09 pm

11:18 pm

12:37 am

Part D

6:28 am

7:14 am

8:00 am

8:56 am

9:42 am

10:28 am

11:44 am

12:30 pm

1:26 pm

2:12 pm

4:58 pm

5:44 pm

6:30 pm

7:26 pm

8:12 pm

8:58 pm

10:14 pm

11:00 pm

11:56 am

12:42 am

158

Board Status - 6:00 am

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

Kanban Post

159

Board Status 6:00 am

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

6

0

0

7

2

4

7

0

6

7

0

0

7

1

8

7

1

2

7

4

8

8

0

0

6

1

8

6

2

4

6

3

0

6

3

6

6

4

2

6

4

8

6

5

4

6

0

6

6

1

2

7

4

2

7

3

6

7

3

0

7

5

4

Kanban Post

160

Inventory Status - 6:00 am


1 Container

1 Container

1 Container 1 Container 1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

161


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

Kanban Post

Line 100

B

/

T

B

/

T

1st Shift 7

5

4

7

3

6

7

3

0

7

4

8

7

4

2

8

1

2

8

2

4

6

4

2

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

8

0

6

8

0

0

8

1

8

8

3

0

8

3

6

8

4

2

6

4

8

162


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

Kanban Post

Line 100

B

/

T

B

/

T

1st Shift 7

5

4

7

3

6

7

3

0

7

4

8

7

4

2

8

1

2

8

2

4

6

4

2

6

5

4

7

0

0

7

0

6

7

1

2

7

1

8

7

2

4

8

0

6

8

0

0

8

1

8

8

3

0

8

3

6

8

4

2

6

4

8

163



1 Container 1 Container 1 Container 1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

164


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

Line 100

Kanban Post

1st Shift 9

5

4

9

3

6

9

3

0

9

4

8

9

4

2

8

4

2

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

1

0

0

0

1

0

0

6

1

0

1

2

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

1

8

8

4

8

165


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

Line 100

Kanban Post

1st Shift 9

5

4

9

3

6

9

3

0

9

4

8

9

4

2

8

4

2

8

5

4

9

0

0

9

0

6

9

1

2

9

1

8

9

2

4

1

0

0

0

1

0

0

6

1

0

1

2

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

1

8

8

4

8

166


Part B

1 Container

Part C


Part A

1 Container

Part D

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

167


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

Line 100

Kanban Post

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

1st Shift

1

0

0

0

1

0

0

6

1

0

1

2

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

1

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

9

5

4

168


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

Line 100

Kanban Post

L

/

T

L

/

T

L

/

T

1st Shift

1

0

0

0

1

0

0

6

1

0

1

2

1

0

2

4

1

0

3

0

1

0

3

6

1

0

4

2

1

0

4

8

1

0

1

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

1

8

1

1

2

4

9

5

4

L

/

T

L

/

T

169

Inventory Status 9:54 am

Part B

1 Container

Part C


Part A

1 Container

Part D

1 Container

1 Container


1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

170


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

Kanban Post

1

1

2

4

1

1

3

6

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

1

2

4

2

1

2

1

2

1

2

4

8

1

1

1

8

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

3

0

1

1

4

2

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

171


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

Kanban Post

1

1

2

4

1

1

3

6

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

1

2

4

2

1

2

1

2

1

2

4

8

1

1

1

8

1

0

4

8

1

0

5

4

1

1

0

0

1

1

0

6

1

1

1

2

1

1

3

0

1

1

4

2

1

1

4

8

1

1

5

4

1

2

0

0

1

2

0

6

L

/

T

L

/

T

L

/

T

L

/

T

L

/

T

172

Inventory Status 10:48 am

Part B

1 Container

Part C


Part A

1 Container

Part D


1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

173

Board Status - 12:02 pm

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

Kanban Post

B

/

T

B

/

T

1

2

0

0

1

2

0

6

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

1

2

4

2

1

2

4

8

1

2

5

4

1

0

0

1

0

6

1

1

2

1

1

8

1

2

4

1

3

0

1

3

6

1

4

2

1

5

4

2

0

0

2

0

6

174


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

Kanban Post

B

/

T

B

/

T

1

2

0

0

1

2

0

6

1

2

1

2

1

2

1

8

1

2

2

4

1

2

3

0

1

2

3

6

1

2

4

2

1

2

4

8

1

2

5

4

1

0

0

1

0

6

1

1

2

1

1

8

1

2

4

1

3

0

1

3

6

1

4

2

1

5

4

2

0

0

2

0

6

175

Inventory Status - 12:02 pm

Part B

1 Container

Part C


Part A

1 Container

Part D

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

176

Board Status 1:58 pm

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

1st Shift

Line 100

Lot Box

Kanban Post

1

5

4

2

0

0

3

5

4

3

4

8

3

4

2

3

3

0

3

1

2

3

2

4

3

1

8

3

3

6

2

3

0

2

1

2

2

1

8

2

2

4

2

3

6

2

4

2

2

4

8

2

5

4

3

0

0

3

0

6

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

E

O

S

B

/

S

2

0

6

177

Board Status 1:58 pm

Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

1st Shift

Line 100

Kanban Post

1

5

4

2

0

0

3

5

4

3

4

8

3

4

2

3

3

0

3

1

2

3

2

4

3

1

8

3

3

6

2

3

0

2

1

2

2

1

8

2

2

4

2

3

6

2

4

2

2

4

8

2

5

4

3

0

0

3

0

6

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

B

/

S

E

O

S

B

/

S

2

0

6

178

Inventory Status 1:58 pm

Part B

1 Container

Part C


Part A

1 Container

Part D

1 Container



1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

1 Container

179


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

2nd Shift

Line 100

Kanban Post

6

2

4

6

3

0

6

1

8

6

1

2

6

0

6

5

5

4

5

3

6

5

4

8

5

4

2

6

0

0

4

5

4

4

3

6

4

4

2

4

4

8

4

3

0

5

0

0

5

0

6

5

1

2

5

1

8

5

2

4

5

3

0

180

Inventory Status - 4:30 pm

Part B

1 Container

Part C


Part A

1 Container

Part D

1 Container

1 Container

1 Container 1 Container 1 Container

1 Container


1 Container

1 Container

1 Container

1 Container

1 Container

181


Part 1 2 3 4 5 6 7 8 9 10

A

B

C

D

Container #

Lot Box

2nd Shift

Line 100

Kanban Post

7

0

0

7

0

6

6

5

4

6

4

8

6

4

2

6

3

0

6

1

2

6

2

4

6

1

8

6

3

6

5

Documents

Kanban Book Final