The KANBAN Strategies

Submitted By:

ASHUTOSH KUMAR JHA (91011)NISHANT SINGH (91039)

KANBAN

Kanban is the Japanese word for card.

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

A sequence of Kanban pulls material through the process.

A signal is seen by the producing department as authorization to replenish.

Types of KANBAN

In Process Kanban

Single-card Kanban

Multiple-card Kanban

The single-card KANBAN system

Two identical containers are filled with an equal amount of parts.

The empty container becomes the signal for replenishment while other container used for production.

The last part in the second container will be consumed just as the first container is returned from being replenished.

Consumption and Replenishment Points

The replenishment point should be located within a short distance from line.

RIP is the primary replenishment location for the storage of materials used for refilling.

Replenishment of RIP can occur from two points:

― Stockroom

― Suppliers

Replenishment Point

Time taken to retrieve the signal container, transport the container to replenishment point, refill the container and return to consumption point.

Determine the inventory remaining in second container.

Daily Demand * Replenishment Days Packet Size

= Quantity

Replenishment Points

Replenishment

Signal

Stock Room

Suppliers

Replenishment Point

Tradeoff is required because minimizing the Replenishment time too much results in increased velocity of material leads to increased material handling cost and traffic.

Review daily demand.

Consumption Point

1Day

Replenishment Point

Replenishment Point

Replenishment Point

3Day

10Day

Line RIP Central Stores Suppliers

Key Issues

Initial setup can represent significant amount of work

Signal can of any form

Labeling should be keeping in mind system design and operator independent

Containers should be of calculated size and not larger or smaller

In-Process KANBAN

Clear and visible signal placed on the downstream side of operation to signal the upstream operation to perform another Takt time amount of work.

IPK provides a temporary parking space for units completed faster than the consuming workstation.

Basically used to pace up the production as per the customer demand.

In process KANBAN(Purpose)

To accommodate minor imbalances on the Lean line.

To maintain the correct sequence of production to meet customer demand.

To alert the operator when it is time to ‘flex’ to the next workstation to help achieve balance on the Lean line.

Multiple Card KANBAN

Uses separate cards to signal move and produce

Used in shared manufacturing processes or processes with long replenishment time

Multiple containers required as the replenishment quantities is very large

Multiple cards are accumulated in a prescribed number to be considered as signal

A ‘Wait/ Work’ sequencing board is used to accumulate these signals

Wait/Work Sequencing Board

Used to determine what to produce and to establish the priority of production based on consumption

‘Move Card’ acts as authorization to move material from replenishment to consumption point

Number of containers used in replenishment area is determined by formula

Each container has another card attached ‘Produce Card’ – card with part no., material description and no. of cards needed to equal a signal

When taken to consumption point, container’s produce card replaced with move card

Produce card moved to Wait/ Work board

Daily Demand * Replenishment DaysContainer Quantity

= No. of Containers & Cards

Produce 1 of ___

Produce 1 of ___

Produce 1 of ___

Produce 1 of ___

Produce 1 of ___

Move

Point of Consumption

Replenishment Area Consumption Area

WorkWait

1 of

1 of

1 of

1 of

1 of

1 of

1 of

1 of 5

6 7 8 9 10

11 12 13 14 15

Wait/ Work Board

Wait/Work Sequencing Board

Once the predetermined no. of Produce cards are returned to the board signal is generated for the production

Provides visibility about how much has been consumed and how much more to consume before producing