Kanban Training
A Comprehensive Training Tool for Using Kanban
Agenda• Defining Kanban• Brainstorming Exercise• Kanban in Depth• How it works• Example of Kanban• Exercise using Kanban• Summary
Defining Kanban
• Kanban is Japanese for “card, ticket, sign, or signboard.”
• Comes from Toyota’s Production System• Manages flow of production and materials
– Used in a JIT “pull” system
After Using KanbanBefore Using Kanban
Brainstorming Exercise
• Goals and hopes for kanban– Why are you implementing this system?
• What will a pull system do for you, the company, your employees?
• What are some things you could do with the potential savings from using kanban?
Kanban in Depth
• Kanban card example• System attributes
– Types of kanban cards
• Functions• Rules
Kanban Card Example
SupplierPull From
ContainerCard 1Order Quan.
Part Number Description
Kanban Card
Special Instructions
System Attributes
• Material vs. Production cards– What to pull/produce– When to pull/produce– How much to pull/produce– Where to pull from
• Visual process helps people
System Attributes
• Kanban is used to eliminate waste and level production
• Typical production looks like this:
Jan
Feb Mar
AprM
ay Jun Ju
lAug Sep Oct
Nov Dec0
2
4
6
DemandProduction
Functions
• Serves as the “nervous system” for production
• Improve and strengthen the factory
Rules
1. Don’t send defectives to the subsequent process
2. The subsequent process comes to withdraw
3. Produce only the quantity withdrawn
4. Equalize the processes
5. Kanban is a means to fine tuning
6. Stabilize and rationalize the process
How Kanban Works
• Push vs Pull activity• Calculating:
– How many kanbans are needed– Finding takt time– How many operators are needed
• ABC Classification
Kanban System
Suppliers Production Process
Final assembly
Material Kanban
Production Kanban
Signal sent from Customer
Customer
Calculating How Many Kanbans• # of Kanbans• Daily output• Mnfting • Safety margin: zero days or as few as possible• Pallet capacity: keep pallet contents small but receive more deliveries
Finding Takt Time
• Takt time is the rate at which products/parts must be produced to fulfill customer orders
• T• O
How Many Operators Needed
• # of operators needed• Need to find TCT
ABC Classification
• A- frequently ordered items, high volume• B- somewhat frequently ordered, medium
volume• C- infrequently ordered, small volume
Example of Kanban
• US Synthetics has been using lean principles, including kanban
• USS was able to stabilize their production, along with their customers’ and suppliers
US Synthetic 7 Years Ago• Batch Processes (Extremely Difficult To See and Fix Problems)
• Production Forecast (Almost always wrong)
• Push Systems (Producing even if there is no demand)
• Hero mentality / Constant Expediting• Working overtime, but never working on the right stuff
Suppl ier Customer
Going Lean, Using Kanban
Suppl ier Customer
US Synthetic Kanban
US Synthetic Customers
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5350%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Customer H On Time Delivery %
Week Number (2011-2012)
1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627282930313233343536373839404142434445464748495051525350%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Customer V On Time Delivery %
Week Number (2011-2012)
Exercise for Kanban
• Demand Analysis
Demand Analysis WorksheetPart # Daily
DemandA-B-C Machine
1 Cycle Time
Machine 2 Cycle Time
Selected Machine
Machine Center Load
A123 35 15 25
B123 25 15 25
C123 75 20 30
AA321 95 20 35
BB321 20 35 50
CC321 15 45 55
XYZ101 50 60 85
Finished Demand AnalysisPart # Daily
DemandA-B-C Machine
1 Cycle Time
Machine 2 Cycle Time
Selected Machine
Machine Cnt Load
A123 35 B 15 25 M1-2 525
B123 25 B 15 25 M1-2 375
C123 75 A 20 30 M1 1500
AA321 95 A 20 35 M1 3325
BB321 20 C 35 50 M2 1000
CC321 15 C 45 55 M2 825
XYZ101 50 A 60 85 M1-2 3000
Summary
• Define Kanban• Brainstorm Exercise• Kanban In Depth
– Material vs. Production Kanban– Rules of Kanban
• Activity Review
Questions?
Reading List• Kanban, Just-In-Time At Toyota by Japanese
Management Association-David Lu• Kanban For The Supply Chain by Stephen Cimorreli• Implementing a Mixed Model Kanban System by
James C Vatalaro• Kanban For The Shopfloor by Productivity Press
Development Team