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Lean Foundations


Kanban – Types and Operating SystemsKanban – Types and Operating Systems

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KanbanWhat is Kanban?

• Card system that controls production & inventory

• Visual pull system vs. a “black box” push system (MRP)

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Categories of Kanban

Instruction

Withdrawal

Kanban

Production Kanban (non lot production)

Triangle Kanban (for lot production)

Interprocess Kanban

Supplier Kanban

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Types of Kanbans & Systems

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• What did a Milk Man do?• What did a Bread Man do?

Milkman vs. Breadman

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Real Life Kanban – Milkman

Replenish What Was Consumed.

Take Empties Back To Factory

Replenish EmptiesDeliver Only What’s Needed

Delivery Milk To House

Constant Time

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Breadman Replenishment • Replenishment Signals

– Empty Rack Inventoried Daily

– Kanban Card Attached At Reorder Point

– MRP Report

• Replenishment Options– Constant Quantity or Constant Time

– Flow through Rack• Material Warehouse

• Withdrawal Kanban Rack At Preceding Process

• Outside Stores

– Production Ordering Replenishment

– Supplier Replenishment• Point Of Use

• Transmitted Signal (Filled From Finished Goods)

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Maturity Path• Stockroom

– Pick List/ MRP– Kitting– Centralized Breadman– P.O.U. Two Bin

Warehouse – Two Bin Line Side– Integrated Supply

• Inventory Turn Goals− One To Two− Once A Month− Twice A Month− Once A Week

• Replenishment Signals

– Empty Bin

– Kanban Card Attached To Bin

– Visual – Lines On Floor

– MRP Report

• Replenishment Options

– Constant Quantity Or Constant Time

– Material Warehouse

– Stockroom

– Supplier

• Vendor Managed Inventory

• Point Of Use At Line or Stockroom

• Transmitted Signal

– EDI

– Production Ordering Replenishment

– Supplier Replenishment

TWO-BIN System

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• The Conveyance is the designated path or standard work that a water spider (material handler) takes to replenish the shelves.

Conveyance or Milk Run Route:

Pitch:• Refers to the time relating to the cycle the “water spider” has to replenish the stock.

• Pitch is a lean concept and is calculated by multiplying cycle time by pack quantity (the number of products per container transferred to finished goods from the work cell).

Definitions

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X X X

XX

X

Flow of workFlow of information

Simple Common Kanban

Kanban Squares

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Rack A

11

22

33

44

AA BB CC

Part 1232Battery Clip

Location A-1-A

55

Kanban Shelving & Labeling Schemes

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Weld Weld KanbanKanban

Bread ManBread Man1 Week supply1 Week supply

Milk Man2 days supply

Based on current Mix

1 day to 1 day to paintpaint

Steps:1. Final assy pulls from paint kanban.2. Paint pulls from Weld kanban3. Welder replenishes weld empties, pulls

from S/M Kanban 4. Paint replenishes paint kanban daily and

puts finished units back in Paint Kanban5. Sheet metal replenishes S/M Kanban

once a week

Sheet Metal Sheet Metal KanbanKanban

WeldWeld

Final AssyFinal AssySheet Sheet MetalMetal

Pain

tP

aint

Kanban – No Cards

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Supplier Kanban With Cards

Lean Materials Strategy Will Maximize Inventory Lean Materials Strategy Will Maximize Inventory Turns Through Supplier Managed InventoriesTurns Through Supplier Managed Inventories

Material Supermarket

SIPLACE 80S

SMT Machines

Withdrawal Kanban Post

Material

Withdrawal

Kanban Card

Supplier delivers Material with Kanban cards from

yesterday attached and picks up today's Kanban cards

Material Handler (Water Spider) delivers material to

supermarket

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Triangle Kanban

• Established for internal lot-processing or batch worksites

• For processes that have lengthy set-up times

• Production time is at a faster pace than that required in the following process

• This type of Kanban has a signaling device built in to prepare for change over

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Visual Management

• Kanban used for batches

Mold PartDescription

Location

Date

Lot Size

Trigger Point

Tool #

Press

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Part Description

Part Number

Location parts will be consumed (customer)

Area defining lot size and time allotted for run

Area defines when product needs to be rescheduled for production

Defines which equipment product is dedicated to run on

Date is hand written by consuming area when pulled

What tool is used to produce this product

Triangle Grid Definition

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Weld Cell #1

AssemblyCell

Weld Cell #2

Triangle Kanbans at Work

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• Took 12 years to flow down kanban within Toyota

• It then took:

– 8 years to have 60% of first tier suppliers on kanban

– 20 years to get 98% of first tier suppliers on kanban

• Only approximately 50% of Toyota suppliers are using kanban systems internally today

Toyota Kanban Timeframe

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• Keep it simple• Develop strategy in phases toward P.O.U.

– Utilize stockroom and warehouse on floor• Then Eliminate stockroom• Then Eliminate warehouse

• Have supplier continue to play larger role• Make it very visual. Should not have to count:

– Label shelves and boxes– Use water levels– Taped /sealed boxes– Color codes, Bar Codes– Egg carton approach, mistake proof system

• Continue to reduce quantity and increase replenishment frequency. Kanbans are inventory (evil) and need to be constantly minimized or eliminated

• As you move from Kanbans to Job Order (MTO) replenishment - upstream processes must adapt. (sets to job order decreases lot sizes i.e. sheet metal)

Implementation keys

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Questions ? Discussion ?

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The Lean EnterpriseThe Lean EnterpriseThe Lean EnterpriseThe Lean Enterprise

Lean Foundations


Lean Foundations


Kanban – Types and Operating SystemsKanban – Types and Operating Systems

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