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8/10/2019 Cms Seminar(1)

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KANBAN SYSTEM

HARI HARAN.K

M.E(C.I.M)2009206028


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Kanban Production Control

SystemKanban:Card or other device that communicates

demand for work or materials from the preceding

station

Kanban is the Japanese word meaning signal

or visible record card

Paperless production control system

Authority to pull, or produce from a downstreamprocess


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Kanban is not for everybody

The conditions necessary for Kanban to work well are:

Smooth production involving a stable product mix

Short setups

Proper machine layout

Standardization of jobs

Improvement activities

Autonomation (autonomous defect control)


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Kanban Control System

Kanban card indicates standard quantity of production

Derived from two-bin inventory system

Kanban maintains discipline of pull production

Q = order quantity

R = reorder point

= demand during lead time

Bin 1 Bin 2

Q - R

R

Reorder

Card

Kanban

a. Two-bin inventory system b. Kanban Inventory System


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Kanban

Each kanban includes info on

Part type

Number of units authorized

Possible additional info

Often used together with transport container

Possibly color-coded to match

Empty container pulls parts / triggers production

Kanban card is work order

Transfer lot size = container size


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Kanban Systems

The first Kanban system was applied by Taiichi Ohno in

Toyota around 1953 to:

Reduce inventory and production cycle time

Improve productivity Kanban and Kaizen

Kanbana card (Japanese term), visual record

Kaizencontinuous improvement

A concept different than Kanban Problem solving by teams


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Kanban Production Control System

Kanban card indicates standard quantity of production

Derived from two-bin inventory system

Kanban maintains discipline of pull production

Production kanban authorizes production

Withdrawal kanban authorizes movement of goods


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Important properties of Kanban System

Production is carried out in multiples of a minimum

quantity or batch.

The number of cards (or containers) in the system is

fixed, hence the total quantity of on-hand and on-order

inventory in the facility is also fixed (fixed-volume pull

system).

Production is only initiated when finished inventory is

removed from the cell, thereby releasing a card (or

container).


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A Sample Kanban


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Types of Kanban System

Single Card Kanban System:

The production activity within the cell is controlled by the

Production Kanban cards, but transportation activity from the

cell is not controlled by the Withdrawal (transportation)

Kanbancards.


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Dual Card Kanban System:

The only difference from the above is that there is an upper

bound on the back orders, which is limited by the number oftransport Kanbans, since they are controlled by the

withdrawal Kanban cards.

Two-stage Kanban System:

Consists of two cells in series.

Simplest version of a multistage Kanban controlled process.

Interactions can be determined in order to get insights.

Types of Kanban System


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Types of Kanbans

Kanban Square

Marked area designed to hold items

Signal Kanban

Triangular kanban used to signal production at theprevious workstation

Material Kanban

Used to order material in advance of a process

Supplier Kanbans

Rotate between the factory and suppliers


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Single ard Kanban System

Storage

area

Empty containers

Full containers

Receiving postKanban card for

product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2


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Storage

area

Empty containers

Full containers


product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2


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Storage

area

Empty containers

Full containers


product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2



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Storage

area

Empty containers

Full containers


product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2



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Storage

area

Empty containers

Full containers


product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2



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Storage

area

Empty containers

Full containers


product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2



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Storage

area

Empty containers

Full containers


product 1

Kanban card for

product 2

Assembly line 1

Assembly line 2

Fabricationcell

O1

O2

O3

O2



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Dual Kanbans


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Dual Kanban system

Process

A

Process

B

P

W Container with withdrawal kanban

Container with production kanban

PWP

XX

XX X

Flow of work

Flow of kanban


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Types of Kanbans


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Types of Kanbans


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Determining Number of Kanbans

where

N = number of kanbans or containers

d = average demand over some time periodL = lead time to replenish an order

S = safety stock

C = container size

average demand during lead time + safety stock

container size

N =dL + S

C

No. of Kanbans =


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Determining the Number of

Kanbansd = 150 bottles per hour

L = 30 minutes = 0.5 hours

S = 0.10(150 x 0.5) = 7.5

C = 25 bottles

ContainersorKanbans3.3

25

5.775

25

5.7)5.0150(

C

SdLN

Solution

Round up to 4 (to allow some slack) or down to 3 (to force improvement)


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Kanban

Z

Step N manufacturer

Z

Step N supplier

Kanban card (and empty container) = request to

supplier to make a container of Z and deliver ASAP

Send request when remaining material = lead timefor replenishment


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Kanban Example

One-card kanban

Low mix/high volume environment

Products X and Z Each has 3 steps performed at same 3

stations A,B,C

One worker per station (aka Point Of Use,

POU)

Storage after each station

Process A+B+CProcess A+BProcess A


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Card located with product throughout the system

Kanban Card For Example

Model number

Replenishment

quantity

X

1

Z product:X product:


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Scheduling Kanban systems

Each stage has its own schedule of Kanbans

This schedule is determined at the Kanban

system design stage

Production is indirectly scheduled by Kanban


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Kanban Control System

Once implemented, a Kanban system acts acontrol system rather than a scheduling

system

It implements a repetitive schedule embeddedin the system

This schedule can be generated by a

scheduling algorithm Simulation can be used to determine the

number of Kanbans, queue size, etc.


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Kanban Control Systems Roles of Kanban

To indicate what is needed at which production stage

To allow various stages to efficiently communicate with

each other

The information can be obtained from the Kanbans

Product name

Code

Volume

Preceding stage and subsequent stage (From .. To ..) Process

Companys production plan is given only to the final line

Every stage automatically knows how much and when to

produce the parts required


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Strategic Implications of JIT

Important for firms focusing on time-based

competition

Cutting cycle times

Improving inventory turnover

Increasing labor productivity

Low cost

Consistent quality Plant organized around product flows

Not used for make-to-order or highly customized

products


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Operational Benefits of JIT

Reduced space requirements

Reduced inventory investment

Reduced manufacturing lead times

Increased productivity Increased equipment utilization

Reduced paperwork

Simplified planning systems

Better production scheduling

Work force participation

Increased product quality


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Implementation Issues

Human costsstress, loss of autonomy

Mitigate by allowing some slack in system

implementing work teams

Job rotations Cooperation and trust between work force and

management

Realignment of reward structures

Layout changes

Stable master production schedules

Short setups

Reliable supplies of materials


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Kanban is:

a) Device authorizing work from preceding station

b) Kanban is the Japanese word meaning

produce

c) Paperless procurement control system

d) Authority to push to a downstream process

OVERVIEW


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OVERVIEW(2)

Typical Kanban includes information on:

a) Kanban number, description, and number of units

authorized

b) Part number, description, and number of units

authorized

c) Kanban number, part number, description, and number

of units authorized

d) Part number, work center, and number of units

authorized


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