Вы находитесь на странице: 1из 28

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 Toyotas Production System
Manages flow of production and materials

Used in a JIT pull system


After Using
Before UsingKanban
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
Kanban Card
Part Number Description

Order Quan. Card 1 Container

Pull From Supplier

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:
6
5
4
3 Demand
2
1 Production
0
Functions
Serves as the nervous system for
production
Improve and strengthen the factory
Rules
1. Dont 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 Produce only the quantity withdrawn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
Material Production Signal sent
Kanban Kanban from
Customer

Suppliers Production Final Customer


Process assembly
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

Supplier Customer
Going Lean, Using Kanban

Supplier Customer
US Synthetic Kanban
US Synthetic Customers
Customer V
Customer H On Time
Time Delivery
Delivery%%

100%
100%
95%
95%
90%
90%
85%
85%
80%
80%
75%
75%
70%
70%
65%
65%
60%
60%
55%
55%
50%
50%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 53
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 53
Week Number (2011-2012)
Week Number (2011-2012)
Exercise for Kanban
Demand Analysis
Demand Analysis Worksheet
Part # Daily A-B-C Machine Machine Selecte Machine
Demand 1 Cycle 2 Cycle d Center
Time Time Machine 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 Analysis
Part # Daily A-B-C Machine Machine Selecte Machine
Demand 1 Cycle 2 Cycle d Cnt
Time Time Machine 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

Оценить