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© Improvement Initiatives (used with permission of author)
The Lean Enterprise Kanban
www.freesixsigmasite.com
Lean Foundations
Continuous Improvement Training
© Improvement Initiatives (used with permission of author)
• Learn what Kanbans are and the different
way the terminology is used in industry
• Understand how to setup a kanban
• Understand how to implement a kanban
system
Objectives
© Improvement Initiatives (used with permission of author)
Kanban Definition
What is Kanban?
• Card system that controls production & inventory
• Visual “pull” system vs. a “black box” push system (ie - MRP)
© Improvement Initiatives (used with permission of author)
• Kanbans are All Around Us
• Kanbans are Inventory
• Inventory Is waste (costly!)
• Goal Is To Minimize Inventory In
Kanbans And Eliminate If Possible
Basic Kanban (Pull signal)
Ultimate Goal of Kanban is to not
have a KANBAN !
One-Piece Flow is the Answer !
© Improvement Initiatives (used with permission of author)
Benefits of Kanban
• Primary
– Eliminate over-production, the #1 waste
– Produce only what is ordered, when ordered, & quantity ordered
• Secondary
– Increase flexibility to meet customer demand
– Reduction in scheduling by Production Control & Manufacturing
– Competitive advantage by sequencing shipments to customers (what they want, when they want it, in the order they want it!)
© Improvement Initiatives (used with permission of author)
• No Cards
– Visual (Tape On Floor)
– Two-Bin or Bin Systems
– Supplier Containers
– Painted floors, i.e. squares, circles
• Card Systems
– Electronic Kanbans - Fax or Emails
– Warehouse Or Parts Racks
– Kanban Boards – Magnetic or Cards
– Containers
– Flow Thru Racks
– Supplier Boxes
Kanban Options
© Improvement Initiatives (used with permission of author)
Categories of Kanban
Instruction
Withdrawal
Kanban
Production Kanban
(non lot production)
Triangle Kanban
(for lot production)
Interprocess
Kanban
Supplier
Kanban
© Improvement Initiatives (used with permission of author)
Production or (In-Process)-Kanban – Provides production instructions for the work center
– Tells the workers exactly the quantity and the type of part to produce
– Used for work centers that produce only one part number or have minimal setups in spite of multiple part number production
• Rectangular – one piece flow production
• Triangular – for small lot production
Withdrawal-Kanban – Inter-Process Kanban
• Delivers order for parts from a preceding process
• Specifies quantity and type of parts to deliver from Location A to Location B
– Later replenishment system – kanban are filled from suppliers finished goods shelf
– Sequenced withdrawal – supplier sequences parts in reverse order for truck loading
– Supplier Kanban • Same as an inter-process Kanban, except it signals
conveyance of part from an outside supplier
Kanban Types
© Improvement Initiatives (used with permission of author)
Job order-Kanban – Issued for each job order
Through-Kanban – When two processes are very close, it doesn’t make sense to issue two
Kanbans. Used where one process directly feeds (conveyor) the next process.
Common-Kanban – Where a withdrawal kanban is used as a production ordering kanban if
the distance between two processes is very short and share the same supervisor.
Emergency-Kanban – Temporary, when there is a defect or problem, can be withdrawal or
production
Other Kanban Types
© Improvement Initiatives (used with permission of author)
• Never Pass on A Bad Part
• The Parts Are Always Withdrawn From The Prior Process
• Produce Only What Is Necessary To Replenish The Quantity Withdrawn
• Level Load Production, Rapid Changeover, Small Lot Production, Zero Defects
• Kanban Is Used To Fine Tune (Not Provide For Major Changes)
• The Process Must Be Capable Of Producing Good Parts (Rational And Stable)
• Need Efficient Methods Of Transportation, Shortest Routes Possible
• Disciplined Organization
• Nothing Is Made or Transported Without A Kanban.
• Kanban Cards Always Accompany the Parts Themselves.
• The Number of Kanbans Should Decrease over time.
Rules of the Kanban
© Improvement Initiatives (used with permission of author)
Kanban – An Information System That Signals the
Need To Start An Event
– Name For Each Individual Signal (Card
Or Otherwise)
Purpose – Control The Flow of Production by
Providing Information Which
Interconnects Upstream And Downstream
Processes At Every Level
Implementation – Usually A Piece Of Paper in a Vinyl
Envelope Or Container
– Outline Markings On The Floor
– Most Common Is Two - Bin System
Summary Definition
© Improvement Initiatives (used with permission of author)
GEMBA FLOOR WALK Go and see where you could implement Kanban!
© Improvement Initiatives (used with permission of author)
The Lean Enterprise Kanban
www.freeleansite.com
Lean Foundations
Continuous Improvement Training