Free Training Excerpt

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Free Training Excerpt

• Full presentation available for purchase at
  www.leandepot.com
• Use promotion code kbtrain for a 5 discount
• Full presentation includes
• Kanban types
• Kanban triggers
• Kanban methods
• Kanban calculations
• Kanban visual boards
• Kanban Technology
• And more

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Introduction To Kanban

• 1st Hear, Then See, Then Do
• Because there is no substitute for experience

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Agenda

• Brief Lean Discussion
• Kanban Triggers
• Kanban Methods
• Kanban Calculations
• Kanban Visual Boards
• Technology Kanban
• Wrap Up

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LEAN House Without Waste
5
Traditional MRP
Planning
Demand Management
Replenishment Forecasting
Demand Forecast
Customer Order Backlog
Master Production Scheduling
Supply Management
Explode B.O.M.s
Operations Routings
Material Requirements Planning
Raw Material Inv - Qty on Hand - Qty on Order
Rough Cut Capacity and Load Plan
Standard Costing
FG Inv Qty On Hand
Planned Order Releases
Production Plan
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Pull vs. Push
Kanban Cell
Supplier
Customer
I got my product on day 1!!!! ?
Cell
Customer
Supplier
Day 1
Day 2
Day 3
Day 4
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BACKGROUND TO KANBAN
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A visual replenishment technique which utilizes
standard containers, each of which has a card
designating what and when to purchase or produce
an item.
Kanban
KANBAN CONTROL BOARD

• Japanese for CARD or SIGNAL.
• Enhances customer response time, lowers
  inventory, and reduces cost.
• Is a driver of continuous process improvement.

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TYPES OF KANBAN TRIGGERS
MARKED SPACES
CARDS
LIGHTS
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Different Kanban Methods

• Internal
• External
• 1 Bin (min/max)
• 2 Bin
• Multiple Card
• Automated

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Multiple Card

• As product is used, signal is generated
• Ordered as soon as box/package is opened

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Multiple Card

• Most flexible form of kanban
• Utilizes supplier package quantity as standard
  container size
• Most disciplined for employees
• Easy to reduce kanban levels by taking away a card

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• Determining a Kanban Level

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Determining a Kanban Level
Need the following 1. Average Daily Demand 2.
Lead Time from Supplier 3. Suppliers Package
Quantity
(510)50 20
5 Cards
Formula (Average Daily Demand Lead Time)
Buffer Suppliers Package Quantity
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Now You Try!!!
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KANBAN CALCULATIONS
Your company has a level daily demand of 10
pieces per day Supplier is located next door and
gives next day delivery Package Quantity is five
pieces per box The supplier is 90 on time, and
your daily demand has always and will never move
from 10 pieces per day What should your total
number of Kanban Cards be???
(A) Avg. Daily Demand _____________ (B) Lead
Time _____________ (C) Buffer _____________ (D
) Package Quantity _____________
2
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• Kanban Visual Boards

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Kanban Visual Board
Visual Boards Show
Desired Inventory Level Current Inventory
Level If material has been ordered Supplier of
material
When material is due in (lead time) If material
is late If should re-look at level Location of
material
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What is wrong with this picture?
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MRP (Push) vs Kanban (Pull)
MRP (push)
MRP - Material Resource Planning-the purchasing
of raw materials upon projected demand regardless
whether consumption is taking place or not.
Kanban (pull)
Kanban - raw materials are given a predetermined
quantity to keep on hand and consumption triggers
replenishment.
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KEYS TO A SUCCESSFUL KANBAN SYSTEM
Benefits

• Position the Kanbans in the most practical
  location.
• The material should be pulled rather than pushed.
• Material should be located so FIFO can be used.
• Use the supplier package as the natural Kanban.
• Only active material should be at the
  workstations.
• Never produce or move material without a signal.
• Never pass on a known defect.
• Work to eliminate a card from the system
  periodically.

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Questions Answers!!!!
Live With Intention