productvity and quality management

8/8/2019 Productvity and Quality Management

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PRODUCTIVITY AND QUALITYPRODUCTIVITY AND QUALITY

MANAGEMENTMANAGEMENT

..K-A-N-B-A-N .

GROUP---1 T.Y.B.B.A- B


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KANBAN

JUST-IN-TIME

PULL SYSTEM

LEANMANUFACTURIN

G

J USTJ UST--ININ--TIMETIMEy A highly coordinated processing system in

which goods move through the system,and services are performed, just as theyare needed

y An inventory strategy that strives toimprove a business's return on investment by reducing in-process inventory andassociated carrying costs.

y To meet JIT objectives, the process relieson signals or Kanbany Thus, Kanban is directly associated with

JIT

PULL SYSTEM

M aterial is pulled through the system whenneeded.Reversal of traditional push system wherematerial is pushed according to a schedule.Forces cooperationPrevents over & under productionRelies on customer requests

LEAN MANUFACtURING

C an be defined as integrated set of activitiesdesigned to achieve high volume productionusing minimal inventories(raw materials,WIP & finished goods)Involves the elimination of waste inproduction effort Also involves the timing of productionresources.


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KANBANKANBAN--CONCEPTCONCEPTy C ard or other device that communicates

demand for work or materials from thepreceding station

y Kanban is the Japanese word meaningsignal or visual card.

y M aintain discipline of pull productiony Authorize production and movement of

goodsy Facilitates what is need, where it is need,

when it is needed.


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KANBAN SIGNALSKANBAN SIGNALSWhen the produc e r a nd us e r ar e not i n visualco n tact, a card ca n be us e d

When the produc e r a nd us e r ar e in visualco n tact, a lig h t or flag or em pty spot o n the floorm ay b e ad eq uat eUsually e ac h card co n trols a sp e cific qua n tity orparts

Multipl e card syst em s m ay b e us e d if t he re ar e seve ral co m po nen ts or diff e ren t lot siz e sSeve ral diff e ren t ka nba n te chn ique s m ay b e em ploy e d ( m ark e rs, em pty co n tai ne rs, troll eys,bins, e tc.)


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KANBAN SIGNALSKANBAN SIGNALS

1.1. User removes aUser removes astandard sizedstandard sizedcontainercontainer

2.2. Signal is seen bySignal is seen bythe producingthe producingdepartment asdepartment asauthorization toauthorization toreplenishreplenish

Part numbersmark location

Signal marker on boxes


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KANBAN BASIC OPERATING SYSTEMKANBAN BASIC OPERATING SYSTEM

SUPPLIER FACTORY STORE

FACTORY FLOOR


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FORMS OF KANBANFORMS OF KANBANy Production kanban

authorizes production of goods

y Withdrawal kanbanauthorizes movement of goods

y Kanban squarea marked area designated to hold items

y Supplier kanbanrotates between the factory and suppliers


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KANBAN PROCESSKANBAN PROCESS

W ork W ork cell cell

Raw Raw Material Material Supplier Supplier

Purchased Purchased PartsParts

Supplier Supplier

Sub Sub--assembly assembly

Ship Ship

KanbanKanban

KanbanKanban

KanbanKanban

KanbanKanban

Finished Finished goods goods

Customer Customer order order

Final Final assembly assembly

KanbanKanban


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EE--KANBANKANBANy E -Kanban systems can be integrated

into E RP systems.y Facilitates real-time demand signaling

across the supply chain and improvedvisibility.

y Help to eliminate common problemssuch as manual entry errors and lost cards.

y Better tracking of supplier lead andreplenishment times.


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Kanba nKanba n Re plis hmen tRe plis hmen t syst emsyst em

Kanban s represent replenishment signals that are usuallymanual and highly visible.

An empty bin that is moved to the supply location to

trigger replenishment.

The system provides support for external devices.

Kanbans can be sourced from an external supplier or aninternal organization

Kanbans are generally replenishable and cycle throughthe system from full to empty.


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.NO.NO-- CARDCARD

With this No Kanban C ard Feature, kanban cards are eliminatedand replaced with a wireless Kanban Replenishment System.

Integrated system is designed to eliminate all the non-valuedadded movement and handling of physical kanban cards with awireless Kanban Replenishment System.

This system knows how each kanban is replenished and bywhat type of vendor.

This function accelerates the kanban replenishment systemwithout the additional burden and delay of physical kanbancard circulation


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Kanba nKanba n inven tory syst em sinven tory syst em s

This system analyzes the actual usage of our client's products todetermine the specific type of shipment needed.

We do this by determining the economic order quantity ( E OQ).

Your KanBan size is based on your estimated annual usage of thepart and the packaging requirements.

With this information we create a system of inventorymanagement that includes stocking an extra shipment of parts.

This saves shipping time and costs, keeps the customer'sproduction line moving, and ensures that the customer will alwaysget their parts when they need them .


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TYP E S OF KANBAN


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One card syst emOne card syst em

y A signal is sent back from the consumingprocess to supplying process (or supplier).This is a signal:

y To send some more (a transfer batch), via abuffer stock.

y To produce some more (a process batch), at the supplying work centre.


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Input output co n trolInput output co n trol ka nba nkanba ny Sometimes called the C onWip (constant work

in process) system, this signal travels directlyfrom the end of a line or section to the

preceding section or raw material stores.y In this case the supply chain is treated as one

unit rather than a series of linked operations.y So, as one transfer batch is completed

(output) another is launched on the first operation (input), thus ensuring that work inprocess cannot build up.


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Kanba nKanba n accu m ulatoraccu m ulator

y In this method Kanban signals areallowed to accumulate at the supplyingwork centre until the production batchsize is reached.

y In this case buffers can be depleted orexhausted depending on the

accumulation rules. Also becausebuffers can be exhausted, slightly highermixes can be accommodated.


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Dual card syst em sDual card syst em sy There are in fact now two types of two card system.y The first method separates the replenishment (send

some) signal, which is produced from the Kanbansystem, from the "produce" signal, which is producedby a scheduling system such as M RP. The purpose of each of the cards is as follows:

1. The scheduling system says which job is next.2. The Kanban says make it now. (I need some.)y The second variant of this method generates the

second card (after authorisation) as a result of one ormore replenishment requests in a similar way toKanban accumulators above


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y In some situations it is more convenient toreplenish items used, by fixed frequencydeliveries (or collections), rather than

respond to fixed quantity replenishment requests.y This method forms the basis of supplier "top

up at point of use" systems, where a supplier

visiting your point of use will top up stocks toa predefined maximum level.

Variabl e Qua n tity (fix e dVariabl e Qua n tity (fix e dfreq uen cy) Syst emfreq uen cy) Syst em


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...VIDEOGRAPHIC PRESENTATION...VIDEOGRAPHIC PRESENTATION


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Functio ns of Functio ns of Kanba nKanba n

y Production M anagement Tool.y Visual C ontrol Tool.y Kaizen Tool.


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Bene fits of Bene fits of Kanba nKanba n

y Reduce Inventoryy Improve work flowy Prevent Overproduction.y Improves responsiveness to changes in

demand.y Reduces waste and scrap.y Provides flexibility in production.y Increases Output.y Reduces Total C ost.


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Lim itatio ns of Lim itatio ns of Kanba nKanba n

y Surges in mix or demand causeproblems.

y It is less effective in shared-resource

situations.y Kanban in itself doesn't eliminatevariability.

y Kanban systems are not suited formanufacturing environments withshort production runs, highly variableproduct demand, poor quality products,and a multitude of product types.


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Lim itatio ns of Lim itatio ns of Kanba nKanba n

y A breakdown in the kanban system canresult in the entire line shutting down.

y The throughput of a kanban system is not managed but is instead a result of controlled WIP and known cycle times.


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The location where a predetermined standardinventory is kept to supply downstream processes.E ach item in a supermarket has a specific location

from which a material handler withdraws products inthe precise amounts needed by a downstreamprocessAs an item is removed, a signal to make more (such

as a kanban card or an empty bin) is taken by thematerial handler to the supplying process

Supermarket


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A small stock of every i t e m sits in adedicated location with a fixed spaceallocation. C ustomers come to the storeand visually select items.An electronic s ign al goes to the regionalwarehouse detailing which items have

sold. The warehouse prepares a (usually)daily rep l eni shm en t of the exact itemssold.

C ont.


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Mod e rn Sup e rm ark e ts Mod e rn Sup e rm ark e ts

y Sign als come from checkout scanners.y They travel electronically (usually once

a day) to the warehouse.y Smaller stores still use visual systems.

Here, a clerk walks the aisles daily.y From empty spaces he deduces what

sold and orders replacements


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Te scoy In the Tesco system, we have seen

example of a kanban driven productionsystem, dedicated to a single product.

y Here is a more elaborated Tesco holdingthree different references, each havingits kanban.

y Production operator receives "orders"through kanban cards returned afterconsummer picked his goods.


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y Kanbans are placed to be visible, on ascheduling panel per product type. Theoperator understands visualythat MAUVE products are less numerousin stock, consistently with the rule: o neka nb a n = o ne pr oduct .

y The operator will changeover production

to manufacture two MAUVE units, and if nothing changes, change again forone ORANGE unit, whichdont kanbanis.. BLUE.


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Con t.y GREEN If kanban cards are all in green zones,

operator chooses next production.y ORANGE If one product reference has its

kanban cards overflowing into orange zone,he'll change his production for this reference.Proper adjustment of zones (stocks levels)allows normal delivery.

y RED If one product reference has its kanban

cards overflowing into red zone, this meansabsolute emergency. Operator has to changeimmediately to this reference and expedite assoon as a minimum quantity is available.


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ARIGATOU GOZAIMASU ( Japa ne se thank you)( Japa ne se thank you)

y AKSHAY KOTHARI-167y RAHUL DE ORAH-164y GAURAV SHAH-156y KE VAL DE DHIA-141y ROHAN ME NDON-123y NIKUNJ AGARWAL-106

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