OM_PPT 02 Kanban.ppt

KANBANKANBAN

Sanjay Choudhari

Indian Institute of Management Indore

KANBAN

• Japanese’s ‘signboard’• Method Toyota used for implementing JIT• Each work station has a fixed # kanbans.• In order to produce, you need both material to

work on, and an available kanban.

KANBAN Control• Two kinds of information required at each

process:– When to produce an item?– When to transfer an item one process to next

process?• KANBAN cards instruct workers to produce or

transfer parts

How does a KANBAN card work?

• Important operating rules– Always attach the KB card to the part that is

produced or transferred.– If all KB cards are attached, do nothing at this

operation.

• KANBAN ensures that– There is no over-production of parts.– No allowance for defective parts.– Defective parts can’t be passed on to subsequent

process.

Flow of work

32

KANBAN

How is this Different?

• Processes can become idled (blocked) or starved• This makes you painfully aware of problems in

your system.• Material moves through the system so quickly no

in-process recordkeeping is needed.

Importance of Flow

Ohno…….Ohno…….

Kanban is a tool for realizing just-in-time. For Kanban is a tool for realizing just-in-time. For this tool to work fairly well, the process must be this tool to work fairly well, the process must be managed to flow as much as possible. This is managed to flow as much as possible. This is really the basic condition. Other important really the basic condition. Other important conditions are leveling the product as much as conditions are leveling the product as much as possible, and always working in accordance possible, and always working in accordance with standard work methods.with standard work methods.

Elements of KANBAN

1. - Work Centers

2. - Inbound Stockpoint / Wc

3. - Outbound Stockpoint / Wc

4. - Material Handling System

5. - Standard Size Containers

6. - Part Number

7. - Fixed Daily Production Schedule

8. - Withdrawal Card (Part # , Source Wc ,Destination Wc)

9. - Production Card (Part # , Using Wc)

KANBAN Rules

1. All containers holding parts must have a card (except when in process)

2. Following wc must PULL parts from preceding wc

3. Containers must always be full

Other KANBAN Type

– Two basic cards• Production Kanban• Withdrawal Kanban

KANBAN system for two production centers

Center 1Center 1 Center 2Center 2

P PP

Store

P

W

Holding Area for WC 2

W W W

Production ordering kanban post

Withdrawal kanban post

Production flow

P Production ordering Kanban

W Withdrawal Kanban

P


Center 1 Center 2

P PP

Store

P

W


W W W



Production flow


W Withdrawal Kanban

P


Center 1 Center 2

P PP

Store

P

W


W W W



Production flow


W Withdrawal Kanban

P


Center 1 Center 2

W


W W W



Production flow


W Withdrawal Kanban

PP P

P

P


Center 1 Center 2

W


W W W



Production flow


W Withdrawal Kanban

PP PP P


Center 1 Center 2

W


W W W



Production flow


W Withdrawal Kanban

PP PPP

StoreShelf No. 5E215 Item Back No.A2-15 Preceding Process

Item No. 35670507 FORGING

Item Name DRIVE PINION B-2

Car Type SX50BC Subsequent Process

MACHINING

Box Capacity Box Type Issued No. M-6

20 B 4/8

Withdrawal Kanban

StoreShelf No/ F26-18 Item Back No. A5-34 Process

Item No. 56790-321 MACHINING SB-8

Item Name CRANK SHAFT

Car Type SX50BC-150

Production-ordering Kanban

KANBAN

𝑘 = Expected demand during lead time + Safety stock𝑆𝑖𝑧𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟

𝑘 = DL (1+ S)𝐶

k = Number of kanban card setsD = Average number of units demanded over some time periodL = Lead time to replenish an orderS = Safety stock, as a percentage of demand during lead timeC = Container size

The Kanban System

Receiving postKanban card for product 1

Kanban card for product 2

Fabrication cell

O1

O2

O3

O2

Storage area

Empty containers

Full containers

Assembly line 1

Assembly line 2

Single-Card Kanban System

The Kanban System

Storage area

Empty containers

Full containers



Fabrication cell

O1

O2

O3

O2

Assembly line 1

Assembly line 2


The Kanban System

Storage area

Empty containers

Full containers



Fabrication cell

O1

O2

O3

O2

Assembly line 1

Assembly line 2


The Kanban System

Storage area

Empty containers

Full containers



Fabrication cell

O1

O2

O3

O2

Assembly line 1

Assembly line 2


The Kanban System

Storage area

Empty containers

Full containers



Fabrication cell

O1

O2

O3

O2

Assembly line 1

Assembly line 2


The Kanban System

Storage area

Empty containers

Full containers



Fabrication cell

O1

O2

O3

O2

Assembly line 1

Assembly line 2


The Kanban System

Storage area

Empty containers

Full containers



Fabrication cell

O1

O2

O3

O2

Assembly line 1

Assembly line 2


Other Kanban Signals

• Cards are not the only way to signal need

• Container system

• Containerless system

Other Kanban Signals

Documents

OM_PPT 02 Kanban.ppt