KANBAN_ystem

Page 11 of 12 Revision Date: 06/04/03
7 wastes
No. Type of Waste Description 1. Waste of Over Production: Producing over customer requirements, producing unnecessary materials / products, or producing to soon. 2. Waste in Waiting (Time): 3. Waste in Transportation: Time delays, idle time (non value added time) Multiple handling, delay in material handling, unnecessary handling or transportation (non value added conveyance) Unnecessary processing, steps or work elements/ procedures (non value added work). Producing unnecessary inventory, holding or purchasing unnecessary inventory, RS, WIP, FG. Waste of motions, excessive handling, unnecessary steps of motion (non value added motions). Correction of errors or rework, scrap (quality problems)
A
A
X
Rack 2
A
A
The material handler comes on frequent schedules and pick up empty boxes and Delivers full boxes Empty Containers
Rack 1
Rack 3
12 1 2 3
Standardized routes delivering small containers on a frequent schedule (once per hour or less). More frequent deliveries lower material inventory at operations.
Full Full Full
Different signal can be used : -Empty box - red space on the floor
Full
Empty dolly signals replenishment.
A-108
Empty Full Empty
Operator pushes out empty dolly & container then pulls next dolly into position.
Part: Side Shield Part No: 9873214 Std. Pack: 60 Min. 2 Max. 5 • Labels affixed to rack using Velcro backed clear plastic pockets. • Labels located directly below containers on the front & back of rack. • Label content includes: Part name, Part number, Standard pack size, Minimum and Maximum Quantity. • Labels are 5 ½ x 3 ½ inches for standard flow racks and 3 x 2 inches for pipe style flow racks. • Racks identified by section and shelf levels.
inventory of each part at its point of use. • The minimum/maximum inventory level is necessary to prevent: 1) running out of parts 2) having more parts than required at the point of use. • This min/max level is set by calculating the: - Kanban loop cycle - Point of use quantity requirements (i.e. Min. 2 hours)

2 3 4 5
Parts Picking
Receiving Staging Area
Receiving Docks Receiving Docks
Blue Dolly Conveyance Route
Orange Dolly Conveyance Route
Next Delivery Cycle Staging
Empty packaging return on roller
Empty packaging
Picking area for the train Roller
Example : Courbouton
Some pictures
Empty containers Kanban
Definition : Kanban system in which a visual signal triggers part replenishment on line.
Visual signal can be : • an empty box • an empty dolly • an empty rack • an empty floor space • a collapsed box • a red mark on racks
So…what’s different?
• replenishment on demand vs. scheduled push • Every product has a specific number of designated racks. • Lot sizes are smaller – more frequent Changeovers required. • Less inventory on the line • FIFO (First-In-First Out) versus FISH (First-In-Still-Here) or FINCO ( First-In-Never-Come-Out )
Learn
See
Empty box Exchange
An empty box is a signal to the material handler for replenishment
Line Side Storage Small Lot Delivery
EMPTY RACK
EMPTY BOX
Empty Dolly Exchange
Learn See
4. Waste in Processing:
5. Waste of Inventory:
6. Waste of Motion:
7. Waste of Producing Failures:
Kanban Requirements
• Establish and maintain a minimum and maximum
3
Train station: loading Train station: unloading
4
5
Tour
Example : Courbouton
Small parts storage (new layout)
Big parts storage (new layout)
Example : Courbouton
Empty Dollies Parts Picking
CHI DET NY BOS PHI MIN
Returnable Container Sorting Area
Small Container Conveyance & Central Material Storage
Central Material Storage
Part: Adjuster Part No: 9981427 Std. Pack: 90 Min: 1 Max: 3 Stack: 3 High Part: Pan Part No: 4563273 Std. Pack: 75 Min: 1 Max: 3 Stack: 3 High
Full Route driver delivers dolly & full container based on signal. Full Full
Empty containers Kanban
Kanban with empty containers
Empty containers Kanban
Kanban takes different forms: • Cards • Empty Containers • Empty Dollies • Electronic Signals • Electronic Kanban • Production Pull (Bill Of Material) • Timed Deliveries
There must be a plan for every part!
Kanban CardDelivery Route
Central Material Storage