Kanban or Pull Production System

7/27/2019 Kanban or Pull Production System

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Sreejith Bhattathiri MFM-798


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The Pull System Material is pulled through the system when

needed

Reversal of traditional push system wherematerial is pushed according to a schedule

Forces cooperation

Prevent over and underproduction

While push systems rely on a predeterminedschedule, pull systems rely on customer

requests


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Japanese word for card

Heart of JIT System

Scheduling system that can immediately and

clearly communicate demands of customer tothe delivery system

Authorizes production from downstream

operations Pulls material through plant

May be a card, flag, verbal signal etc.

Kanban Production Control System


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Used often with fixed-size containers Add or remove containers to change production rate

Kanban card indicates standard quantity of

production

Derived from two-bin inventory system

Kanban maintains discipline of pull production


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Level production (balance the schedule) in orderto achieve low variability of the number of partsfrom one time period to the next.

Avoid complex information and hierarchicalcontrol systems on a factory floor.

Do not withdraw parts without a Kanban.

Withdraw only the parts needed at each stage. Do not send defective parts to the succeeding

stages.

Produce the exact quantity of parts withdrawn.

Need of Kanban


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Visibility function

The information and material flow are combinedtogether as Kanbans move with their parts (work-inprogress).

Production function

The Kanban detached from the succeeding stage

fulfils a production control function which indicates

the time, quantity, and the part types to be produced.

Functions of Kanban


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Inventory function

The number of Kanbans actually measures the amountof inventory. Hence, controlling the number of Kanbansis equivalent to controlling the amount of inventory.


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Supplying

Process

Customer

Process

product

Production Card

Finished Goods

Store

Withdrawal Card

product

Kanban System


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A Sample Kanban


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Fabrication Area

Supply/Storage Area

Assembly AreaReceiverPost

Productionorder Post

P.O.

P.O.

P.O.

W.C.

KANBAN SEQUENCE


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ReceiverPost


W.C.

1. An assembly worker gets a Withdrawal Kanban from the receiver post thattells how many of each item to withdraw from Supply/Storage.

Fabrication Area

Supply/Storage Area

Assembly Area


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ReceiverPost


P.O.

W.C.

2. The assembly worker goes to the supply point and gets a cart with all the itemsspecified on the withdrawal card.

Fabrication Area

Supply/Storage Area

Assembly Area


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ReceiverPost


P.O.

3. There is a Production Order card on the cart that the assembly worker removes andplaces on the receiver post where someone from fabrication will get it.

W.C.

Fabrication Area

Supply/Storage Area

Assembly Area


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ReceiverPost


P.O.

4. The assembly worker places the withdrawal kanban on the full cart and takes itback to the assembly area to assemble.

W.C.

Fabrication Area

Supply/Storage Area

Assembly Area


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ReceiverPost


P.O.

5. Someone periodically removes the production order kanbans from the receiver post,reviews and sorts them for priority, and places them on the production-order post.

P.O.

Fabrication Area

Supply/Storage Area

Assembly Area


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ReceiverPost


6. A fabrication worker comes to the Production-Order Post and gets aproduction-order kanban and an empty cart.

P.O.

Fabrication Area

Supply/Storage Area

Assembly Area


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ReceiverPost


P.O.

7. Fabrication produces the items specified on the Production-Order Kanbandelivers them to the supply/storage area.

Fabrication Area

Supply/Storage Area

Assembly Area


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Primary Kanban: Travels from one stage to another among main

manufacturing cells or production preparation areas.

The primary Kanbans are two kinds, one of which is called`withdrawal Kanban (conveyor Kanban) that is carriedwhen going from one stage to the preceding stage.

The other one is called `production Kanban and is used toorder production of the portion withdrawn by the

succeeding stage.

Types of Kanban


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Supply Kanban: travels from a warehouse or storagefacility to a manufacturing facility

Procurement Kanban: travels from outside of acompany to the receiving area.

Subcontract Kanban: travels between subcontractingunits.

Auxiliary Kanban: may take the form of an express

Kanban, emergency Kanban, or a Kanban for a specialapplication.


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N = DT/C

Where n = total number of containers

D = Demand rate of the using work centre

C = container size in number of parts, usuallyless than 10 per cent of daily demand

T= time for a container to complete an entire

circuit (lead time)

Calculation of Number of Containers


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The Kanban system works well in repetitiveproduction environments (Line flows/product

focused) Ifyou are able to achieve small lot sizes and short set-up

times, and

Ifyour suppliers are close by and can make frequent

deliveries using a just-in-time system.

Kanban Use


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Reduce inventory level

Less confusion over sequence of activities

Less obsolescence of inventories while in storage

Smaller floor space requirements for storing inventory

Reduce lead time

Improved quality

Higher employee productivity

Greater system flexibility

Benefits


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Documents

Kanban or Pull Production System