Simple Steps to Implement Kanban in Lean Manufacturing
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This document discusses lean manufacturing techniques, specifically kanban systems. It describes how kanban cards are used as visual signals to authorize production in a pull system. Two main types of kanban systems are explained: single card systems where one card authorizes movement and production; and two card systems where separate cards authorize movement between processes and production within a process. Examples of actual kanban cards are also provided.
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Simple Steps to Implement Kanban in Lean Manufacturing
- 9. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) A Kanban is a Visual Information System established to maintain the DISCIPLINE of a JIT System on the shop floor. Kanban (Japanese) : Card or Visual Record. In The Modern Lean Terminology…….., A SIGNAL THAT AUTHORIZES PRODUCTION
- 11. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) Single Card Kanban In a Single Card Kanban System, the operator of a down stream operations requires a Production Card and the necessary Material to be authorized to begin processing. He/she simply removes the Card and sends it back to the upstream process, signaling production to replenish the material used by his/her station prior to processing the job.
- 12. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) When stock is removed place production card in hold box. Production card authorizes start of work. Full Container Production Box Workstation Kanban card Container being filled Container being emptied When stock is removed place production card in hold box. Production card authorizes start of work. Outbound Stock Point Outbound Stock Point Outbound Stock Point
- 13. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) Two Card Kanban System A Two Card Kanban is used when WIP cannot be effectively handed from one process to the next, thus necessitating an Inbound Stock Point and an Outbound Stock Point for processing stations. Mainly this system is utilized in heavy transaction, high complexity parts (huge number of parts) In this System Two Cards are used : • Move (Conveyance) Card : To Authorize the Movement of material • Production Card : To Authorize the Production.
- 14. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) Part number : 33311-3501 Container capacity : 50 No. of kanban released : 7 of 12 Downstream work center: K123 Stock location no.: A-12 Stock location no.: A-07 Upstream work center: Y321 Two Card Kanban System – Move Card
- 15. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) PROCESS 1 PROCESS 2 1 New stock moved into Process 2 Move kanban detached 2 Move kanban attached to new stock 3 Production kanbans direct the production sequence B Production kanban attached to finished quantity C OUTBOUND STOCK AREA INBOUND STOCK AREA MOVE KANBAN (1-2-3) Each process has an inbound and an outbound stock area. The inbound area contains raw materials used in the process. The outbound area holds completed output from the process. When Process 2 begins to consume the contents of a container, the Move Kanban is taken off the container and brought to the outbound stock area of Process 1. There the Move Kanban is attached to a new, full container, which is taken back to the inbound stock area of Process 2, ready for use. Dispatch Box Production kanban detached, placed in dispatch box A
- 16. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) Work Center no.: Y321 Part number to be produced: 33311-3501 Container capacity: 50 units Stock capacity at which to store: A-07 Materials Required: Material no. 33311-3504 Stock location: A-05 Part no. 33825-2474 Stock location: B-03 Two Card Kanban System – The Production Card
- 17. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) PROCESS 1 PROCESS 2 1 New stock moved into Process 2 Move kanban detached 2 Move kanban attached to new stock 3 Production kanban detached, placed in dispatch box A Production kanbans direct the production sequence B Production kanban attached to finished quantity C OUTBOUND STOCK AREA INBOUND STOCK AREADispatch Box PRODUCTION KANBAN (A-B-C) A Production Kanban is attached to every container in the outbound stock area at Process 1. When Process 2 comes to remove a container of parts, the Production Kanban is taken off and put in a dispatch box for Process 1. Process 1 may make parts for several other processes, therefore, it builds the new parts in the order in which the kanban are placed in the dispatch box. When a container is full, the Production Kanban is attached to it and it is placed in the outbound stock area ready for withdrawal by Process 2.
- 37. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) It is seen as a pure production method having little or nothing to do with the surrounding environment Kanban focuses on the mathematical complexities of Kanban or elaborate abstract rules of operating Kanban with inadequate attention to its practicality and implacability on the shop floor. We need to keep the above misconceptions to rest by developing an easy to implement set of operating rules in the plant.
- 39. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) Three Phases Phase Particulars Induction Implementation Evaluation Model Area Selection, Training, Design of Kanban and Board 5S, SMED, Multi Skilling, SPC and Operating Rules. Pilot Run, Evaluation against Set Values of Parameters
- 40. ®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates) Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055 Regd Off: Bangalore; Representations: Gulbarga (Admin) Hyderabad, Pune, New Delhi, Nagpur, Kolhapur, Cochin, Ahmedabad, UK (Cambridge), Barcelona (Spain) & South Africa (Johannesburg) MASTER SCHEME Month 1 Month 2 Month 3 Month 4 Month 5 1 2 3 4 1 2 3 4 1 2 3 1 2 3 1 2 3 Selection of model area Layout improvement Multifunction workmen training Reduction of setup time by SMED Pilot run
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