The Lean Enterprise
Kanban – Types and Operating Systems
Lean Foundations
Continuous Improvement Training
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Kanban
What is Kanban?
• Card system that controls production & inventory
• Visual pull system vs. a “black box” push system (MRP)
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Categories of Kanban
Instruction
Production Kanban
(non lot production)
Triangle Kanban
(for lot production)
Kanban
Withdrawal
Interprocess
Kanban
Supplier
Kanban
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Types of Kanbans & Systems
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Milkman vs. Breadman
• What did a Milk Man do?
• What did a Bread Man do?
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Real Life Kanban – Milkman
Replenish What Was Consumed.
Take Empties Back To
Factory
Delivery Milk To House
Replenish Empties
Deliver Only What’s Needed
Constant Time
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Breadman Replenishment
• Replenishment Signals
– Empty Rack Inventoried Daily
– Kanban Card Attached At Reorder Point
– MRP Report
• Replenishment Options
– Constant Quantity or Constant Time
– Flow through Rack
• Material Warehouse
• Withdrawal Kanban Rack At Preceding
Process
• Outside Stores
– Production Ordering Replenishment
– Supplier Replenishment
• Point Of Use
• Transmitted Signal (Filled From Finished
Goods)
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TWO-BIN System
• Replenishment Signals
Maturity Path
• Stockroom
– Pick List/ MRP
– Kitting
– Centralized Breadman
– P.O.U. Two Bin
Warehouse
– Two Bin Line Side
– Integrated Supply
– Empty Bin
– Kanban Card Attached To Bin
– Visual – Lines On Floor
– MRP Report
• Replenishment Options
– Constant Quantity Or Constant
Time
– Material Warehouse
– Stockroom
• Inventory Turn Goals
− One To Two
− Once A Month
− Twice A Month
− Once A Week
– Supplier
•
Vendor Managed Inventory
•
Point Of Use At Line or
Stockroom
•
Transmitted Signal
– EDI
– Production Ordering
Replenishment
– Supplier Replenishment
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Definitions
Conveyance or Milk Run Route:
• The Conveyance is the designated path or standard
work that a water spider (material handler) takes to
replenish the shelves.
Pitch:
• Refers to the time relating to the cycle the “water spider” has to
replenish the stock.
• Pitch is a lean concept and is calculated by multiplying cycle time
by pack quantity (the number of products per container transferred to
finished goods from the work cell).
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Kanban Squares
X
X
X
X
X
X
Flow of work
Flow of information
Simple Common Kanban
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Kanban Shelving & Labeling Schemes
A
1
B
C
Part 1232
Battery Clip
Location A-1-A
2
3
4
5
Rack A
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Sheet
Metal
Kanban – No Cards
Final Assy
Weld
Paint
Sheet Metal
Kanban
Weld
Kanban
Milk Man
2 days supply
Based on current Mix
Bread Man
1 Week supply
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1 day to
paint
Steps:
1. Final assy pulls from paint kanban.
2. Paint pulls from Weld kanban
3. Welder replenishes weld empties, pulls
from S/M Kanban
4. Paint replenishes paint kanban daily and
puts finished units back in Paint Kanban
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5. Sheet metal replenishes S/M Kanban
once a week
Supplier Kanban With Cards
Supplier delivers Material
with Kanban cards from
yesterday attached and picks
up today's Kanban cards
Material
Withdrawal
Kanban Post
SIPLACE 80S
SMT Machines
Material Handler (Water
Spider) delivers material to
supermarket
Material Supermarket
Lean Materials Strategy Will Maximize Inventory
Turns Through Supplier Managed Inventories
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Triangle Kanban
• Established for internal lot-processing or batch
worksites
• For processes that have lengthy set-up times
• Production time is at a faster pace than that required in
the following process
• This type of Kanban has a signaling device built in to
prepare for change over
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Visual Management
• Kanban used for batches
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Part Description
Location parts
will be consumed
(customer)
Part Number
Area defining lot
size and time
allotted for run
Area defines when
product needs to
be rescheduled for
production
Date is hand written
by consuming area
when pulled
Defines which
equipment product is
dedicated to run on
What tool is used to
produce this product
Triangle Grid Definition
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Triangle Kanbans at Work
Weld
Cell #1
Assembly
Cell
Weld
Cell #2
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Toyota Kanban Timeframe
• Took 12 years to flow down kanban within Toyota
• It then took:
– 8 years to have 60% of first tier suppliers on kanban
– 20 years to get 98% of first tier suppliers on kanban
• Only approximately 50% of Toyota suppliers are
using kanban systems internally today
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Implementation keys
•
•
Keep it simple
Develop strategy in phases toward P.O.U.
– Utilize stockroom and warehouse on floor
• Then Eliminate stockroom
• Then Eliminate warehouse
•
•
Have supplier continue to play larger role
Make it very visual. Should not have to count:
–
–
–
–
–
•
•
Label shelves and boxes
Use water levels
Taped /sealed boxes
Color codes, Bar Codes
Egg carton approach, mistake proof system
Continue to reduce quantity and increase
replenishment frequency. Kanbans are inventory
(evil) and need to be constantly minimized or
eliminated
As you move from Kanbans to Job Order (MTO)
replenishment - upstream processes must adapt.
(sets to job order decreases lot sizes i.e. sheet
metal)
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Questions ? Discussion ?
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The Lean Enterprise
Kanban – Types and Operating Systems
Lean Foundations
Continuous Improvement Training
freeleansite.com
© Improvement Initiatives (used with permission of author)