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Determination of Number of Kanbans
Bhaskara PI semester PEST
National Institute of Engineering, Mysore-08
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SupplyingProcess
Assemblyprocess
part
Production Card
Finished parts
Store
Withdrawal Card
part
Kanban Information system
Kanban (pull) SystemWithdraw/Pull only what is neededReplenish what is withdrawn
Overall BenefitsPrevents overproductionReduces inventory
Fig.1. 2 kanban card information system10/22/2013 5:57 AM 2
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Kanban Information system
Fig.2. kanban card10/22/2013 5:57 AM 3
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Process of Kanban sizing
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Determine the daily demand
Calculate No. of kanban cards
or
quantity per kanban
Print Kanban
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Withdrawal Systems
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Withdrawal system
Constantquantity,
non constant cycle
Constant cycle,
non constant quantity
Constant cycle systemforsupplier kanbans
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Used within the plant
Shorter lead time
Improved processes
where,
S = safety co efficient (should not be less than 0.1)
C = container capacity
D = daily demand
lead time (days)= Tprocess+Twaiting+Tconveyance+Tkanban collecting
i). The constant quantity, non-constant cyclewithdrawal system
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Avg. D X lead time X (1+ S)
Total No. of kanbansC
economic lot size+ (D X S)Total No. of kanbansC
Larger lots
Smaller lots
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E.g.: 1. D=100
lead time=0.5 day
C=10
S=0.2
No. of kanban = [100*0.5*(1+0.2)]/10
= 6
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i). The constant quantity, non-constant cyclewithdrawal system.
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ii). The constant cycle, non-constant quantitywithdrawal system
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Kanban No. is fixed
Demand doubles then, only kanban circulation doubles
Quicker problem identification
D X (order cycle + lead time + safety period)
Total No. of kanbans C
Used within the plantRelatively larger lead time (process/conveyance)
Order quantity No. of kanban detached by regular collection X C
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ii). The constant cycle, non-constant quantitywithdrawal system.
E.g.: 2. D=500
order cycle= 0.2
lead time=0.5
Safety period=0.2
C=40
No. of kanban = [500* (0.2+0.5+0.2)]/40
= 11.25 ~ 12
Order quantity = 3 * 40
= 120
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iii). The constant withdrawal cycle system forSupplier kanbans
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100 1+ 2Total No. of kanbans [[1]] * 0.2
5 6
Total No. of kanbans 14
D 1+ conveyance intervalTotal No. of kanbans [[No. of days spent for conveyance]] *
C No. of convey/dayS
Used forSupplierkanbans
geographical distance
longer lead time
slightly varying quantity
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