PDF | Lean manufacturing has been the buzzword in the area of manufacturing for past few years especially in Japan. The Kanban system is. PDF | Kanban system is inventory stock control system that trigger signal for production of product based on actual customer requirement. PDF | In this paper, JIT (Just-In-Time)-KANBAN literature survey was The blocking mechanisms in the kanban system are also discussed.
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The Kanban System explained by real examples. The Kanban system is a way to realize pull. Real pictures with real case explained. presentation of Kanban system and how a company can use this tool for managing the inventory. This method is one of the most used methods to reduce the. Kanban (+ Page Lean PDF). Last updated by You will often hear the words kanban system, kanban, and kanban card, used somewhat interchangeably.
JIT is a collection of managerial techniques that aim to rationalize and optimize the production process. A key feature of this approach is the use of the pull mechanism, where production is triggered by final demand for products, rather than by the supply of components. Kanban is a well known example of one such technique for putting JIT production into action. The Integrated Kanban System IKS is an advanced computer-based support tool to help in the design and implementation of a kanban system. It maintains all the benefits of traditional kanban techniques, promotes lean production and supports both real time and historical monitoring and evaluation.
The ordering, though, is not necessarily from an external supplier. It may also be from an upstream process or some other department within your own company. It may even be an order from a warehouse. You will often hear the words kanban system, kanban, and kanban card , used somewhat interchangeably. This sample shows some of the information you will likely see on a kanban card.
Click the image to download a free kanban card generator The kanban concept is versatile, and can be applied in many variations both on the shop floor and in the lean office.
A kanban may be a location on a floor, a cart, a pallet, or anything else you can think of that conveys a message about what to do regarding the materials. A kanban tells… An upstream operator to produce more parts production kanban A material handler or water strider to pull parts from another location withdrawal or transport kanban A downloading group to download more material download kanban A kanban system is one of the key ingredients to transitioning to pull and to the implementation of Standard Work.
It is worth noting that kanban systems, due to the tight linking to standard processes , work best with high quality , low variation parts and materials. Kanbans rely heavily on standardization and 5S to operate effectively. In all likelihood, you have a kanban system in your home.
Dig down in your box of blank checks from your bank and find your last checkbook. On the front of it you will see a close approximation to a kanban card. That piece of paper with the reorder information on it is essentially the same as a kanban card used by your company.
The main difference between that reorder slip and the kanban card, though, is that the former does not have as tight of a link to your actual usage of checks, nor does it factor in the procurement time it takes to receive the new checks. Click the image to see how kanban cards work.
So, think about how the check process works. As you get towards the end of your box of checks you tear off the reorder form and drop it in the mail. Granted, many banks are transitioning to an online ordering system, but the principle is the same. The paper kanban card signals an action to download more.
So what, exactly, are kanbans supposed to do?
Kanbans act to control inventory levels and to make replenishment systems more visual. But be careful about one incorrect assumption that people frequently make about kanbans: Kanbans do not reduce inventory.
A common misconception is that using kanban will reduce inventory. Not true. All kanban does is provide a simple and effective way to manage materials.
If the amount that the kanban tells you to order is set too high, you will be sitting on a lot of excess.
If it is set too low, you will run out. So, kanban just puts the structure in place to manage the reordering process, whether from an internal warehouse or upstream process, or from an external supplier. In my ficticious company, we have a rack for each Go-Kart chassis. The empty rack is a kanban that assembly sends back to fabrication to signal them to produce another one. The racks wind their way through the whole production process. In a two bin system, there might be ten Go-Karts per rack.
In my system, we have twenty racks that each hold a single vehicle. So why kanban and not a computer system?
Because it is visual. It is easy to miss something on a computer report. It is hard to walk into a production cell and not notice that a bin is empty, or that a card is missing.
Problems become immediately apparent. Of course, many kanban system link into a computer system—a downloadr may just scan a barcode to place an order. But the visual management at the point of use for a kanban is hard to beat.
Plus, operators can be trained to review parts levels in their area. If they notice that both bins are nearly always full, they can point out an opportunity to reduce inventory. If the safety stock is nearly used up with each kanban cycle, they can see that the inventory is set too low. This is generally used on mixed model lines. There are a set number of items stored in designated spots.
When the downstream process pulls an item, a kanban card or the empty space signals to the upstream process what to build next. The quantities of each type of item are dictated by the model mix. It can be confusing to manage productivity for upstream processes using this type of system when the items come from different areas.
As effective as kanban systems are for helping structure your inventory management efforts, there are some common pitfalls to avoid. Kanban systems only work when teams follow the rules consistently. If rules are followed sporadically, there will almost certainly be parts shortages. Material with no kanban card attached, cards lying around, and past due cards without any action are all abnormal conditions and indicators of problems. People like to hedge. Kanban systems work like beacons.
When suppliers are unreliable, parts quality is poor, or lead times are too long, kanban systems make the problems very noticeable. When demand changes, the kanban quantities will have to change as well.
For permanent changes, the quantity should be adjusted. Microsoft Excel and Word work together nicely to print cards quickly merge functions when demand changes. Different style cards can signal different things.
Triangle cards may be internal. Suppliers may be color-coded. Parts racks can themselves be kanbans. Use kaizen to improve the kanban process.
In kanban systems, your life tends to get easier. Switching to kanban can be a chore lots of cutting and laminating and Velcro , and it can be unnerving to see your safety net of inventory go away, but most people soon see the benefit. Once the system is in place, dropping cards for operators is a breeze. Many companies even have material handlers who come past all the work areas collecting cards and empty bins and replenishing materials.
When this is done with a standard process, the person is known as a water strider or mizusumashi in Japanese. The biggest hang-up people have is in maintaining the discipline to keep the system running effectively. It is easy to stick a card in your pocket and bring it home on accident. Or during crunch time, it is easy to grab from the second bin before you drop a card.
Be careful—a kanban system, as robust as they can be, will fail if the process is ignored. Lead by example. Walk through the work areas every day looking for problems with materials. Stress following the process.
Focus on making the system visual so problems are immediately visible. When you transition to kanban , start with the highest value parts first use an ABC inventory analysis.
Kanban systems can be confusing until you see them in action. If you are unfamiliar with them, try to find a local company that uses them, and arrange a tour. Many companies are willing to work with other local businesses to share best practices.
When you have a good idea of what a common process is supposed to look like, try to implement one of your own. Start out by trying to make a few cards in a single area and work out the kinks in your processes. Once you gain a better understanding and learn a little more how you want to run things in your own organization, it is time to stabilize the processes and start rolling them out in other work areas. I want to stress that point: If you contrast this situation to a traditional batch and push manufacturing system, you absolutely can and likely will see a one time reduction in the inventory.
As your manufacturing or operating system becomes more stable, and lead times are further reduced, you can reduce the quantity of kanban signals and take a further reduction. All of that said, I agree that if you are going into a kanban implementation with the thought of immediate fast and easy instant inventory reduction without doing the hard work of changing anything else in your value stream, you will be sorely disappointed.
In some cases, though, if the quantities before kanban were too low, having a system highlights that and tells you to add inventory.
The point of the comment is that kanban is an inventory control mechanism. Some SKUs will come down and some will go up. Love that you mentioned the value stream and the need for other improvements, though. It helps to have that message echoed repeatedly.
Thank you for the response Jeff! I have seen a few cases where inventory was too low — and kanban did make a incremental increase so I see your original point.
I am very appreciative of your website and products. This is one of the best resources I have found for customizable lean materials. I came to this site originally for Policy Deployment training materials — and have found that and a lot more.
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