kanban for bfl
TRANSCRIPT
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KANBAN Study
BFL
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- Need for KANBAN at BFL
- What is KANBAN
- KANBAN System An Overview- Benefits
- Implementation steps Summary
- KANBAN walk
CONTENTS
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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
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- Need for KANBAN at ALB
- What is KANBAN
- KANBAN System An Overview- Benefits
- Implementation steps Summary
- KANBAN walk
CONTENTS
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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.
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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)
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TYPES OF KANBAN
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- Need for KANBAN at ALB
- What is KANBAN
- KANBAN System An Overview- Benefits
- Implementation steps Summary
- KANBAN walk
CONTENTS
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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
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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
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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.
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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
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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
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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
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KANBAN Trolley distribution
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KEY TIMINGS
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- Need for KANBAN at ALB
- What is KANBAN
- KANBAN System An Overview- Benefits
- Implementation steps Summary
CONTENTS
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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
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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
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- Need for KANBAN at ALB
- What is KANBAN
- KANBAN System An Overview- Benefits
- Implementation steps Summary
CONTENTS
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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.
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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.
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KANBAN METHODOLOGY
Jr-4 (J7/J9)Jr-4 (SF) Jr-3Pin1&Pin2
Sup
ermarket
Sup
ermarket
MATERIAL FLOW
INFORMATION FLOW
Move Card
Production
Card
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Thank You