GBE-KPO-2-016-00 Kanban (Pull Replenishment) 伟创力精益

GBE-KPO-2-016-00 Kanban (Pull Replenishment) Rev.03
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Table of Contents
Contents Slide(s)
Overview & Scope Objective – Kanban Background – Why Kanban The Function of Kanban System Kanban Information / Material Flow - Reference Kanban Kanban Rules - The Use of Kanban Kanban Check List Kanban Flow & Kaizen - Reference Kanban Rack & Kaizen - Reference Kanban Card / Post & Kaizen - Reference Kanban Card (Data Collection) & Kaizen - Reference Kanban Card Process Flow & Kaizen - Reference Part Replenishment from Supermarket to Point of Use Part Replenishment / with Kanban / Kaizen – Reference Kanban Evaluation Check-list Exercise
GBE-KPO-2-016-00 Kanban (Pull Replenishment) Rev.03
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Overview & Scope
Overview
Kan means "card" in Japanese, and the word "ban" means “Signal“ Kanban is a Japanese term for “signal.” Used in Supply Chain Management, Kanban is a card or other signal used to indicate the need for inventory replenishment.
Scope
1. This Lean methodology provides significant impact on business performance by reducing inventory, lowering overhead for scheduling & expediting, and improving customer satisfaction with consistent, shorter lead-times. This provides a dramatic positive impact on the balance sheet and income statement. 2. The Kanban provides strategies, tools and techniques used in Operations to indicate the need for inventory replenishment. 3. A system built on Kanban principles is a ‘Pull’ method of keeping Production Lines optimally stocked with Parts and Components when they are needed and in the Right Quantity. 4. In today's highly competitive environment, a successful Kanban deployment is often critical to business viability. As a Process, an order for depleted Inventory is immediately placed, either via a Kanban Card or electronically through a computerized Kanban program.
REVISION 03
REVISION HISTORY DESCRIPTION OF CHANGE Document formatted as per DMS policy
ORIGINATOR Amol Dharmadhikari
RELEASE DATE December 11, 2008
This document is proprietary and confidential property of Flextronics.
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GBE-KPO-2-016-00 Kanban (Pull Replenishment) R– What / Why Kanban???
• Manufacturing often complain that they incur large inventory-carrying costs with an MRP system, yet can still run out of key parts. These stock-outs stop production, delay customer shipments, increase premium freight charges and disrupt plant operations by forcing unnecessary and expensive changeovers. • In the current MRP World there is often no clear record of how many times stock-outs occur or which parts repeatedly stock-out. Stock-outs also can lead to an overreaction of parts buying, followed by excess inventory, which is often carried for months after a stock-out. • • • Keeping expensive inventory is a waste of resources, including working capital, storage space, and the manpower needed for handling. Unlike MRP forecast-driven replenishment, a Kanban system re-orders parts and components based on actual consumption at the point of use. The simplest version of this is the “two-bin” method. In this case, an operator has two bins of material. One is being consumed and another is full.
GBE-KPO-2-016-00 Kanban (Pull Replenishment) Rev.03
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Background – What / Why Kanban???
• • • • When the first bin is empty, the operator continues working using the second bin. Meanwhile, the empty bin is sent to the producing station, an obvious signal for replenishment. A full one returns before the operator runs out. In another Kanban example, a manual Kanban card travels with its inventory and contains information such as the description of the item or part number, and its location. Each card has a number and is used to trigger an order for replenishment when an item is consumed. Manual Kanban benefits are severely limited when an external supplier enters the supply chain. The number of cards, and tracking them become unmanageable. An electronic Kanban system can remedy this problem. Card information is translated into a bar code that is scanned and electronically communicated at each stage of the replenishment cycle (consumption, shipping, receiving). In this way, electronic Kanban increases visibility and efficiency.
GBE-KPO-2-016-00 Kanban (Pull Replenishment) Rev.03