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The Lean Enterprise Kanban

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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

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Kanban Definition

What is Kanban?

• Card system that controls production & inventory

• Visual “pull” system vs. a “black box” push system (ie - MRP)

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• 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 !

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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!)

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• 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

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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

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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

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• 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

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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

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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