kanban for bfl

7/30/2019 Kanban for BFL

1/25

KANBAN Study

BFL


2/25

- Need for KANBAN at BFL

- What is KANBAN

- KANBAN System An Overview- Benefits

- Implementation steps Summary

- KANBAN walk

CONTENTS


3/25

GRINDING OPERATION WAS THE

BOTTLENECK

* On a 3-shift basis

Soft Module

Capacity: 1200

parts/month

Grinding

Module

Capacity: 940

parts/month

Final Module

Capacity: 1500

parts/month

Dispatching

Need for KANBAN


4/25


5/25

- Need for KANBAN at ALB

- What is KANBAN



- KANBAN walk

CONTENTS


6/25

KANBAN DEFINED

KanbanSystem is an information system that harmoniously

controls the production of the right products in right quantitiesat right time in every process of a factory and also among

companies.


7/25

OBJECTIVES OF KANBAN

There are four objectives of KANBAN

1.Convey information (what and when to produce,

when and where to move)

2.Control inventory (fixed total quantity of parts)

3.Control process (visual are Kanban moving?)

4.Support improvement (gradually reduce no. ofKanban)


8/25

TYPES OF KANBAN


9/25


- What is KANBAN



- KANBAN walk

CONTENTS


10/25

KANBAN AS IMPLEMENTED IN GEARS

A Mix of Production instruction

and parts withdrawal Kanban

Is designed to reduce Forced idle

time due to No Material

System owner is PPC, works in

co-ordination with production

Trigger is based on PPC plan atcomponent-machine level

C id ti hil i P d ti


11/25

Considerations while preparing Production

Plan

PPC will develop and control the production schedulestarting with the final operation (J7/J9)

Capacity variations at each stage i.e. Jr-4, Pin-1&2 &

Jr-3.

Manpower availability. Variety of Dies.

Maintaining of Mini Mkt. stock for avoiding the stock

out situation for Jr-4.

WIP norms

Availability of Shot Blasting output


12/25

KANBAN METHODOLOGY

PPC makes the date wise and shift wise KANBAN

plan as per the date wise Mfg Plan. As per the KANBAN plan, scheduling is done on

KB posts in Grinding Module

Material is made available for machining, 1 shift in

advance at the appropriate machines.

Production, produce the components and attach

KANBANs to them as per color coding in

respective lines.

PPC moves the material with KANBANs.


13/25

KANBAN Card Samples

PRODUCTION KANBAN

PART VISUAL

Trolley type

No. of pcs

A

10

SOFT MACHINING

Part No.

Part Name

F1607811

3rd on MS

PRODUCTION KANBAN

PART VISUAL HARD MACHINNG

Part Name No. of pcs 10

Part No. Trolley type B

WITHDRAWAL KANBAN

Storage

Location

Point of

use

PART VISUAL

Part Name 3rd on MS No. of pcs 10

Part No. F1607811 Trolley type A

A

A

Crank Shaft

D-3306

3rd on MS

F1607811

Turn Blank Store

3rd on MS Cell

3

Jr. Semi Finish


14/25

KANBAN Card Samples

PRODUCTION KANBAN

PART VISUAL

Trolley type

No. of pcs

A

10

SOFT MACHINING

Part No.

Part Name

F1607811

3rd on MS

PRODUCTION KANBAN

PART VISUAL HARD MACHINNG

Part Name No. of pcs 10

Part No. Trolley type BA

3rd on MS

F1607811

A

Crank Shaft

D-3306

3

Jr. Semi Finish


15/25

KANBAN POST

Kanban Post is used as visual display for

triggering Production.

Kanban drop box

Production

Schedule

Key Timings

Production Area

Description

Grinding Module

Die No-

3306/3307/3295

KANBAN

Procedure


16/25

KANBAN Trolley distribution


17/25

KEY TIMINGS


18/25


- What is KANBAN



CONTENTS


19/25

KANBAN IMPLEMENTATION STEPS (1/2)

DetailsStep

Decision of

Material

Information

flow

Design of the

Kanban

resources

Calculations ofResources

Decision of

layout

Study of existing flow, identify stages

Decide the flow type and flow stages Decide mini-markets stages and sizes

Cards color and format

Trolley type and color

Stores for card

Calculate the requirement of the following Cards & its Storage

Trolleys

Kanban boards and posts

Collection boxes

Mini-market areas

Input material area

Kanban post physical location

Material flow routes

Decision on

Kanban

Mechanics

Weekly micro level planning of M/C Loading

Key timings for material movement

Batch sizes for material movement


20/25

DetailsStep

Decision on

Kanban

Mechanics

Training of

executives and

associates

Prepare roll-out

plan

Monitor and

improve

Weekly micro level planning of M/C Loading

Key timings for material movement Batch sizes for material movement

Train line executives and associates

Train associated lines executives and

associates

Train material handlers

Prepare rollout plan, stage-wise is preferable

Monitoring by

Daily checks

Periodic audits

Problem solving and moving ahead

Roll out in other areas

KANBAN IMPLEMENTATION STEPS (2/2)

Order

resources as

per rollout plan

Order resources


21/25


- What is KANBAN



CONTENTS


22/25

KANBAN METHODOLOGY

KANBAN BOARD will made available near to Jr-4

& Jr-3. KANBAN BOARD will contain two cards with

different colors, one card (Production card) will

authorizes production on Jr-4 & another card

(Move card) authorizes movement of palletcontaining Jr-3 output parts to supermarket while

moving pallet to supermarket need to detach

production card Jr-4 begin to produce another

standard pallet to replace the one that was justtaken.

Production card on Jr-4 need to be planned for SF

& J7/J9 after completion of every 36 parts.


23/25

KANBAN METHODOLOGY

No of move card depends on set-up change on Jr-

4 (SF to J7/J9), because when set-up changes Jr-3output will be consumed by Jr-4.

When IP for J7/J9 were moved from supermarket &

consumed on Jr-4 operator will need remove the

move card and need to keep in drop box availableon KANBAN BOARD.

Material handler returns cards to appropriate

KANBAN BOARD.


24/25

KANBAN METHODOLOGY

Jr-4 (J7/J9)Jr-4 (SF) Jr-3Pin1&Pin2

Sup

ermarket

Sup

ermarket

MATERIAL FLOW

INFORMATION FLOW

Move Card

Production

Card


25/25

Thank You

kanban for bfl

Documents