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The Lean Enterprise

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The Lean Enterprise An Introduction to Kanban concepts Lean Foundations Continuous Improvement Training Learn what Kanbans are and the different way the terminology ... – PowerPoint PPT presentation

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Title: The Lean Enterprise


1
The Lean Enterprise
  • An Introduction to Kanban concepts

Lean Foundations Continuous Improvement Training
2
Objectives
  • 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

3
Kanban Definition
  • What is Kanban?

Kan "card"
ban "signal"
  • Card system that controls production inventory
  • Visual pull system vs. a black box push
    system (ie - MRP)

4
Basic Kanban (Pull signal)
  • Kanbans are All Around Us
  • Kanbans are Inventory
  • Inventory Is waste (costly!)
  • Goal Is To Minimize Inventory In Kanbans And
    Eliminate If Possible

Ultimate Goal of Kanban is to not have a KANBAN !
One-Piece Flow is the Answer !
5
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!)

6
Kanban Options
  • 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

7
Categories of Kanban
8
Kanban Types
  • 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

9
Other Kanban Types
  • Job order-Kanban
  • Issued for each job order
  • Through-Kanban
  • When two processes are very close, it doesnt
    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

10
Rules of the Kanban
  • 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.

11
Summary Definition
  • 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



12
  • GEMBA FLOOR WALK
  • Go and see where you could implement Kanban!

13
The Lean Enterprise
  • An Introduction to Kanban concepts

Lean Foundations Continuous Improvement Training
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