What Is Kanban
Kanban is a Japanese word that mean scard or signal.
At the core of pull production, a signals upstream operations to deliver what is needed, in the quantity needed, and when needed.
For a pull system to work effectively, demand variations must be smoothed. Distributing both the volume and mix of total customer orders evenly over sequential time periods through load leveling can satisfy variable demand.
This achieves a steady and consistent work flow. With erratic demand patterns, higher inventory levels must be utilized, and this is accomplished by applying a policy variable to modify the calculation.
Takt time is an important element used to determine the rate at which product must be produced to satisfy market demand. It is determined by dividing the available production time by the rateof customer demand.
For example, if customer demand is 240 parts per day and the factory operates 480 minutes per day, takt time is 2 minutes. It sets thepace of production to match the rate of customer demand.
A kanaban system can be manual or automated. The various methods to trigger replenishment are physical ,min/max , "things" , electronic , interplant, and single enterprise.
|
Types of kanban |
|
|
Type of kanban |
Description |
|
Transport |
Permission for material to be moved from the upstream supplying work cell to the downstream consuming work cell |
|
Withdrawal |
Requests that material stored in one inventory location be delivered to a process step or other inventory location |
|
Replenishment |
A request from an inventory location or a process step that the goods it has used up need to be replaced |
|
Production |
Authorizes a process step to produce the needed replacement material |
|
Supplier |
Requests material external to the enterprise, such as from another division, plant, or a supplier |
|
Emergency |
Is used to designate that defective parts have occurred and need to be replaced immediately |
|
Express |
Generated when an unexpected shortage has occurred and authorizes expediting for production replenishment |
By applying kanban you will :
- Integrates all processes to one another and connects the value stream to customer demand.
- Improves flexibility to respond to customer demand.
- Simplifies the procurement process.
- Uncovers hidden waste in processes.
- Empowere Employees to sequence work based oncurrent conditions.
- Execution-based scheduling.
- Eliminate unnecessary paperwork is .
- Supports waste elimination of overproduction.
- Reduce inventory for finished goods, raw materials,and subassemblies.
