KANBANGroup 10

Mohamad Izzudin B Abdul HamidB050810048

Mohd Khuzaimi B Mohd SallehB050810002

Mohammad Ikmal B Mohamed B050810223

PRODUCTION PLANING CONTROL

INTRODUCTION OF KANBAN

Kanban is a Japanese word for card that means “singboard” or “signal”.

The card is an authorization for the next container of material to be produced.

It is a scheduling system that helps to determine what to produce, when to produce it, and how much to produce.

Many different sorts of signals are used, but the system is still called kanban.

MORE KANBAN

When the producer and supplier are not in visual contact, a card can be used.

When in visual contact, a light or flag or empty spot on the floor may be adequate.

Kanban is a simple, effective and visual system of managing and ensuring the product flow.

Maintain discipline of pull production.

CONCEPT OF KANBAN SYSTEM

Kanban scheduling systems operate like supermarket.

A small stock of every items sits in a dedicated, location with a fixed space allocation.

KANBAN SYSTEM

The factory principle is applied to a machining and assembly operation.

A more realistic example would probably involve at least two pallets.

The widget assembler would start working from the second pallet while new stem-bolts were being made to refill the first pallet.

Producer

•100 stem-bolts on a pallet.

•Bolts used and pallet is empty.

•Then, a person will takes a card that was attached to the pallet and sends it to the stem-bolt manufacturing area

Manufacturi

ngarea

•Receive card (new pallet of stem-bolts is not made until a card is received).

•Pallet of stem-bolts is then manufactured.

•Pallet refilled and sent back to the widget assembler.

KANBAN’S NUMBER

EXAMPLE A production manager is working in a cellular manufacturing system for an automobile parts. He has to process an average of 250 parts per hour in the cell. The capacity of each container is 30 parts and one kanban is attached to all the containers. The time to receive new parts from the previous workstation is 25 minutes. Factory maintains a safety stock factor of 15%. Determine the kanban needed for the plant.

SOLUTION

D = 250 parts per hourL = 25 minutes = 25/60 = 0.4167 hourSS = (0.15)(250)(0.4167) = 15.6C = 30 parts

No. of Kanban, N = DL + SS

C = (250 x 0.4167) + 15.6

30

= 3.993 ≈ 4

7 STEP TO IMPLEMENTING KANBAN

1) Conduct Data Collection2) Calculate The Kanban Size 3) Design The Kanban4) Train Everyone5) Start The Kanban6) Audit and Maintain The Kanban7) Improve The Kanban

STEP 1: CONDUCT DATA COLLECTION Collect the data necessary to characterize

the production process. This data will allow you to calculate the

kanban quantity. Data collect:

The number of parts produced Changeover times Downtime Scrap Levels

STEP 2: CALCULATE THE KANBAN SIZE

Calculate the kanban container size based on current conditions, not based on future plans or desire.

The initial calculations will utilize the data collections to calculate a replenishment interval.

Replenishment interval = establish the order quantities

STEP 3: DESIGN THE KANBAN

Develop a design to support production requirements based on current conditions.

To create design of kanban:Select the signaling mechanism for the

kanbanDevelop the rules for operation of the

kanbanCreate a visual management plan for the

kanban Finish the design step, pick a start

date, build a plan to support this date and monitor the plan for progress toward hitting this date.

THE KANBAN RULES

1) Each container must have a card.2) Assembly always withdraws from

fabrication (pull system). 3) Containers cannot be moved without a

Kanban card. 4) Containers should contain the same

number of parts. 5) Only good parts are passed along.6) Production should not exceed

authorization.

STEP 4: TRAIN EVERYONE

Before starting kanban, train everyone on how the system will work and on their role in the process.

Develop a simple presentation to explain the process and the visual signals.

Keep the training focused on operating the kanban.

STEP 5: START THE KANBAN Before implement kanban,

make sure all visual management piece in place.

Having the signals set up, control points marked, and the rules completed and coordinated before start.

During the deployment stage, develop a scheduling transition plan and determine the exact point for the change and the amount of inventory required to make the change.

STEP 6: AUDIT AND MAINTAIN THE KANBAN

Auditing is the step that usually gets overlooked in most failed start-ups(identify who will audit).

The auditor will be watching how the scheduling signals are handled.

Taking action prevents the kanban from being pronounced a failure by the operators.

The auditor will also look at future requirements to make sure the kanban quantities meet expected demand.

STEP 7: IMPROVE THE KANBAN Improve the kanban to

reduce inventory quantities.

Reduce the quantities based on improvements made to the production process.

Type of kanbans Withdrawal

(Conveyance) Kanban

Production Kanban

TYPES OF KANBAN

Specifies the kind and quantity of product which a manufacturing process should withdraw from a preceding process. 

FunctionPass the authorization for the movement of

parts from one stage to another.Once it gets the parts from the preceding

process and moves them to the next process, remaining with the parts until the last part has been consumed by the next process.

The withdrawal Kanban then travels back to the preceding process to get parts thus creating the cycle.

Withdrawal (Conveyance) Kanban

A withdrawal Kanban usually

carries

part number

part name

lot size

routing process

name of the next process

location of the next process

name of the preceding process

location of the

preceding process

container capacity

number of container released

Example of Withdrawal Kanban

Specifies the kind and quantity of the product which the preceding process must produce.

Function- release an order to the preceding stage to build the lot size indicated on the card.

Production Kanban

A production Kanban usually

carries information

Part number

Container capacity

Preceding work center number

Raw materials other part types

used in manufacturing at the work center

Example of Production Kanban

KANBAN BENEFITS

1

•Reduces Inventory

2

•Improves Flow

3

•Prevent Overproduction

4

•Improves Responsiveness to Change in Demand

5

•Reduce Waste and Scrap

6

•Provide Flexibility in Production

7

•Increases Output

Kanban will reduce inventory, by 25 to 75%. Saves in terms of rent, electricity, and storage

space. All of the space freed by the implementation of

a kanban system can be used for future expansions or new opportunities.

Reduce Inventory

The speed of moving from one task to another is significantly reduced by the creation of clearly marked flow lanes, kanban cards, and clearly marked labels

Moving material provide the guidance needed to improve the flow.

No queue product. Eliminate waiting time.

Improves Flow

Because parts are only created at the visual signal by the kanban label (link), inventory is much less likely to be overproduced. Resulting in significant savings in the holding of stock

Overproduction is mother of waste(space, cost, expired product, labor cost & etc.)

Prevent Overproduction

Unlike a predictive system, kanban immediately reacts to the environment.

The signal stops production when demand decreases, and when orders begin to increase, the inventory levels will signal the production to begin again.

Improves Responsiveness to Changes in Demand

Products and components are only manufactured when they are needed.

Kanban eliminates overproduction. Raw materials are not delivered until they are

needed, reducing waste and cutting storage costs.

Reduces Waste and Scrap

If sudden drop in demand of product occurs, Kanban ensures production not stuck with excess inventory.

This gives the flexibility to rapidly respond to a changing demand.

Provides Flexibility in Production

Kanban reduces wait times by making supplies more accessible and breaking down administrative barriers. This results in an increase in production using the same resources.

Increases Output

CONCLUSION Kanban is faster, more efficient, and saves

significant money over most other production models.

A kanban system is also far more directly responsive to customer demand.

Kanban is a system that visually indicates when production should start and stop.

KANBAN END