kanban card calculator
TRANSCRIPT
1 7 8
1st 2nd
4
Ready 1 2 3 4 5 6 2 3 4 5
15
Machining 6 7 8 9 7 8
7Fetting 9 10 11 1 10 11
17
15
8th 9th 15th
6 2 3 4 5 6 7 3 4 5 6 2 3 4
9 7 8 1 10 8
1 10 11 9 2 11
1 week over 2nd Week over
0
15th 15th
5 6 2 3 4 5
1 7 8 1 7 8
9 10 11 9 10 11
2nd Week over 2nd Week over
Kanban Bin Calculation Sheet
E+H Monthly Reqt 175Weekly Reqt 44
7
Stage
Ready for Pack co 15 0 60 60 100% 109 5 300 300 175 3Machining 20 15 60 60 100% 255 7 420 120 109 2Fettling 0 20 60 60 100% 146 7 420 300 255 5Shelling 10 0 60 60 100% 73 4 240 180 146 3
Wax Assembly 0 10 60 60 100% 73 3 180 120 73 21020 758 15
Daily Avg Production Reqt (DDQ)
Transit Lead Time (TLT)
Production Lead Time (PLT)
Batch Size (Kanban Qty) KQ
Delivery minimum lot size (DMLS)
% of Schedule Adherence (PSA)
Demand During Lead Time (DDL)
Toal No of Kanban Cards (TNKC)
Total Quantity of Material
Max. Stock
Min. Stock
No of Green Cards: NGC
Wax
2521
111
No of Red Cards: NYC
Kanban Bin Calculation Sheet
A B C D E F G H I J KE+H Monthly Reqt 182Weekly Reqt 46
8
Stage
Wax Injuction/Raw Or 0 2 10 10 100% 15 3 30 1 1 1Assembly/Forging 0 7 32 32 100% 53 3 106 1 1 1Shelling/Machinin 0 2 10 10 100% 15 3 30 1 1 1Pouring 0 2 10 10 100% 15 3 30 1 1 1Fettling 0 2 10 10 100% 15 3 30 1 1 1
0 2 10 10 100% 15 3 30 1 1 1
Daily Avg Production Reqt (DDQ)
Transit Lead Time (TLT)
Production Lead Time (PLT)
Batch Size (Kanban Qty) KQ
Delivery minimum lot size (DMLS)
% of Schedule Adherence (PSA)
Demand During Lead Time (DDL)
Number of Cards Necessary for DDL (Toal No of Kanban Cards) (TNKC)
Total Quantity of Material
No of Green Cards: NGC
No of Yellow Cards: NYC
No of Red Cards:NRC
Ready for Pack condition
Wax
L
300
300
300
300
300
300
Prodn capacity/ Day
Customer Monthly Reqt 1200 300Weekly Reqt 300Definition and Distribution of Kanban Cards *yellow cells are the input fields
Daily demand quantities*(DDQ) 50 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)Transport lead time days*(TLT) 5 Days Vendor lead timeProduction lead time days*(PLT) 0 Days Internal lead time
Container/palett capacity*(Kanban Qty) KQ 32 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)
% of Schedule Adherence (A) 100% Percentage internal attrition or scrap
Delivery minimum lot size* (DMLS) 32 ML hastes Defined according to vendor constrains or work center constraints
No of Location for Stock* NOL 0
Working Shifts/Day 2
Hours/Shift 8
Total Downtime 3
Shift Effn 80%
250 Ml of units A*(DDQ*(TLT+PLT)
Number of Cards Necessary for DDL (TNKC) 45 Number of cards
Safety Margin (No of Cards) 38 Number of cards
Total quantity of material 1450 Ml of units b5 (DDQ) = c11 1290Days of demand coverage 29 Days b6 = (TLT)= B13
0 b7=(PLT) = C13Average customer demand /Hr(Takt Time) 0
b8 KQ D13
Card Distribution b10 (DMLS) =E13
Above Reorder Point >> # of Green Cards NGC 1 b18 (TNKC) H 13
Above Reorder Point >> # of Yellow Cards:NY 7 Red Reorder points
Below Safety Margin >> # of Red Cards:NRC 37 Gre
Safety stock (Percentage of demand during lead time) Demand During Lead Time (DDL)
Total Required Inventory (TRI) = DDQ*(TLT+PLT)*NOL
if IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
7.812537.5
45.3125
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
Customer Monthly Reqt 160 40Weekly Reqt 40Definition and Distribution of Kanban Cards *yellow cells are the input fields
Daily demand quantities*(DDQ) 7 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)Transport lead time days*(TLT) 0 Days Vendor lead timeProduction lead time days*(PLT) 15 Days Internal lead time
Container/palett capacity*(Kanban Qty) KQ 32 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)
% of Schedule Adherence (A) 100% Percentage internal attrition or scrap
Delivery minimum lot size* (DMLS) 32 ML hastes Defined according to vendor constrains or work center constraints
No of Location for Stock* NOL 0
Working Shifts/Day 2
Hours/Shift 8
Total Downtime 3
Shift Effn 80%
100 Ml of units A*(DDQ*(TLT+PLT)
11 Number of cards
Safety Margin (No of Cards) 9 Number of cards
Total quantity of material 360 Ml of units b5 (DDQ) = c11Days of demand coverage 54 Days b6 = (TLT)= B13
0 b7=(PLT) = C13Average customer demand /Hr(Takt Time) 2
b8 KQ D13
Card Distribution b10 (DMLS) =E13
Above Reorder Point >> # of Yellow Cards:NY 3 Red Reorder points
Below Safety Margin >> # of Red Cards:NRC 8 Gre
Safety stock (Percentage of demand during lead time) Demand During Lead Time (DDL)
Number of Cards Necessary for DDL + Earlier stage safety stock Qty(TNKC)
Total Required Inventory (TRI) = DDQ*(TLT+PLT)*NOL
if IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)