IV. Kanban Production Control

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IV. Kanban Production Control
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A. What Is Kanban?

• Japanese Word Card or Visible Record

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B. Toyota Kanban

• Specialized
• 1. Production Kanban (Card)
• 2. Conveyance Kanban

Withdrawal Transport
A.K.A
Milling
Drilling
Ex.
Several Operations for one component Fourth Op.
- Mill Fifth Op. - Drill
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Dual-Card Kanban Flows
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C. Kanban Rules

• 1. One Production (Conveyance) Kanban 10 Daily
  Demand
• 2. Number of Containers for a Component Between
  Two Operations Number of Production Kanbans
  Number of Conveyance Kanbans
• 3. A Worker Needs a Production Kanban for a
  Component to Produce It (Production Kanban Is the
  Only Authorization for Produce)
• 4. A Worker or a Material Handler Needs a
  Conveyance Kanban to a Component to Move a
  Container Form One Operation to the Next.
• 5. Number of Production Card Conveyance Kanbans
  Is a Important Managerial Decision Based Upon
  Parts, Experience, Etc.

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Conveyance Kanban
Part No. Container capacity No. of Kanban
Following work center Stock location No. Stock
location No Preceding work center
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D. Kanban Signals (Pull Signals)

• Card Board Card
• Metallic Cards
• Container (Specific to Part)
• Marked Space on Floor (Hewlett - Packard)
• Colored Golf Balls
• Computer Signals

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E. Comparison of Kanban MRP
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F. Calculations for Number of Kanban Sets
Production Conveyance

• Theoretically - One Container . In practice,

Management direction
Should have enough to last through lead time
Ex. Component xyz Required at drill 200 per
hour Lead time (Material handling Processing
at milling Waiting time at milling)
hours Policy Factor 8 Container size 150
units
(200)(4)(1.08)
884/150 5.76 or 6 Production Kanbans
6 Conveyance Kanbans
150
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G. Other Versions

• Single Kanban - Use Only Conveyance Kanban
• Production Is Controlled by a Daily Schedule
  Production Is Decided in Advance

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Single-Card Kanban Flows
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H. Need for Kanbans

• Perfect J.I.T Does Not Need Kanban, but Kanban
  Needs J.I.T Environments
• Perfect J.I.T Clockwork Mechanism
• Suppliers Fabrication Assembly
• A Person Working on Each Part - One Part at a
  Time Continuously
• All Parts Come Together at the Assembly Stage
• Supply Production Assembly One Piece at
  a Time
• No Storage, Breakdown, Quality Problems, Happy
  Employees
• Mass Production Comes Close to a System Such As
  This.
• Kanban System Needed Only When There Are Machines
  That Make Several Different Parts/Components.
• Significant Distance Between Work Centers
• Some Setups Still Exist (2 Min. - 30 Min.)