Kanban : Pull System2 Basic Principle of KANBAN Updated: June 2nd, 2006
Kanban : Pull System3 Controls production of the right parts, in the quantities, at the right moment, in every stage of production. Updated: June 2nd, 2006
Kanban : Pull System4An instruction for: withdrawing products from thepreceding processProducing the quantity that hasbeen withdrawn Updated: June 2nd, 2006
Kanban : Pull System5Two types of Kanban the Production Instruction Kanban(PIK) the Withdrawal Kanban (WK) Updated: June 2nd, 2006
KANBAN CARD6 DEFINITION: kanban card = communication tool TARGETS: Indicate the part number / part name and the quantity to be produced per card Information on the card - name of the supplier and name of the customer. - point of storage (shopstock) and point of use Updated: June 2nd, 2006
Kanban : Pull System7 From internal customer Batch Building Box WK PIK Assembly line a a aa A A A b c WK WK WK To internal b b b customer B B c c C C Supermarket / shopstock Production instruction Kanban Withdrawal Kanban loop loop Updated: June 2nd, 2006
Instruction Kanban (PIK)81. Production batch = 1 Kanban (no changeover) The production order for the reference. A 1 Kanban corresponds to 1 box to produce2. Production batch = n Kanbans (changeover time) Kanban with batch- building box Updated: June 2nd, 2006
Instruction Kanban (PIK)9 When different references are manufactured in the same process with changeover time, the production order is a pack of Kanban (a batch).The production order is not given until the batch has been constituted . A batch of n Kanbans corresponds to n packaging units to produce. Example: The batch of five Production Instruction Kanbans is the production order. Updated: June 2nd, 2006
Withdrawal Kanban10 The order for withdrawing the reference. It is used between sequencer and production line processes within a site to instruct the internal supply team to pick up the parts from upstream. Updated: June 2nd, 2006
Withdrawal Kanban11 The downstream process at the end of the line The sequencer at the end of the line Circulation of this Kanban must follow two principles: Simultaneous transfer of the parts and the corresponding information (the Kanban is attached to the packaging unit or part) Frequent transfer (several times per shift – if Updated: June 2nd, 2006
Batch Building Box13 DEFINITION: Is a box accumulating the kanban cards in order to build the batch The batch size reflect the flexibility of the production line / machine (Faurecia proposes to invest 10% of the production time in tool change) The batch building box is placed at the end of the line TARGET: build a production batch with a fixed June 2 , 2006 Updated: size nd
END OF LINE STOCK14 DEFINITION: reflect the flexibility and reliability of the machine / production line. This stock: *is designed to contain all product variants (or at least the most demanded) *is located at the end of the machine / production line. TARGETS: allow the customer to pick the parts he needs without waiting the parts to be produced Updated: June 2nd, 2006
WAITING QUEUE15The practical way of maintaining the withdrawal order of the packaging units. It represents the manufacturing sequence of the production line and uses gravity to feed the cards. Updated: June 2nd, 2006
WAITING QUEUE16 DEFINITION: WQ helps to accumulate the batches respecting the FIFO The waiting queue is placed at the beginning of the production line TARGET: give to the production a clear sequence nd Updated: June 2 , 2006 to be respected for the production of the
6 Rules for Effectiveness17 No bad part may reach next process The number of parts in each packaging unit must be identical to the number of parts noted on the kanban The downstream process must withdrawal according to the kanban the exact quantity of the right product at the right time Updated: June 2nd, 2006
6 Rules for Effectiveness18 The output of the upstream process must match the quantity withdrawn by the downstream process The number of Kanbans must been reduced. The number of PIK reflects the stock levels. It is essential to lower the kanban as progress is achieved. The Kanbans must be used to adapt to fluctuations in demand Updated: June 2nd, 2006
ADVANTAGES19 • Respect the customer demand • Produce at the rythm of the customer (Takt Time) • Visualisation of the production management • Regular and controlled production • Improve the reactivity Updated: June 2nd, 2006
Kanban : Pull System20 • Video “Palmela Fixed Batch Kanban” • Kanban Pull Systen Model – Simulation • Shopfloor visit: waiting queue, batch building box, kanban Updated: June 2nd, 2006
Production System Effiency STANDARDIZED WORK TRAINING
Definition – Standardized WorkA timed description of the best possiblesuccession of basic manual tasks for anoperator.It includes:- transformation and control operations- but also movements- other necessary steps included in the cycletime.
Objective Achievement of safety, quality, productivity and delivery performance objectives through: • reduce dangerous movements • apply controls and ability to repeat • correct use of machines • identification and elimination of the 7 wastes • training and evaluation of the operators
Key Factors •Allows the repeatability of the sequence of basic tasks during each cycle with low variability of the process. •Work content may differ according to product options • Separate the man and machine • Reduce frequencial operations (reduce variability) • Quick and efficient treatment process of improvement ideas through the operator
Cycle Time and Takt Time Takt time is a rate that represents, in seconds, the number of parts the customer expect us to deliver Cycle time is a rate, in seconds, at which the product must be produced in order to offset “waste” in the system and achieve the Takt Time needed to satisfy the customer
Work ContentSum of the basic tasks carried out at each workstation to obtaina complete and good product (amount of work for a part)It is measured by timing the cycle of each operator using a cycletime measurement form.The measurement must be based on 20 consecutive cycle times(everything included).Time necessary for self-inspection has to be included.For each operator, we will show the minimum time, wait timeexcluded, as well as the maximun and mean time.
FORMSThe standardized work goal is based on 3forms:• Standardized Work Chart ( #)• Work Combination Table (#)• Standard Operation Sheet (#)
Standardized Work Chart- describes the succession of basic tasksand the position of the operator for each ofthem.- helps to visualize easily the operatormovements and to identify uselessmovements- determines the number of parts betweeneach workstation.
Standardized Work Chart Standardized work chart FAU-F-PS-5006 /1 Operation from: Date:Product: panel Process: welding, assembly to:Takt Time Expected nb Sketch operators w orkstations. Part aw aiting operator parts waiting Break his/her w ork dow n into (e.g. At end of cycle) elem entary tasks corresponding to those in the standard w ork Machine 4 (Welding) Quality com binaison table. inspection 61 s Special hasard or Add sym bols Safety safety action Station 5 (Inspection)Cycle time Movement with part without part Production FP cart 51 s 5 nam e: 2 1 6Expected 3 date:number ofparts waiting 7 10 4 8 Methods name: 9 3 Num ber the operators position date: for each job Quality name: date:
Work Combination Chart- gathers all the basic identified tasks on theStandardized Work Chart and details eachspecific time.- helps differentiate times walking andwaiting from working on the workstation.- allows to evaluate the difference betweencycle time and takt time and to verify thatoperators do not wait for the machine.
Standard Operation Sheet- details all the instructions to realize anoperation at a workstation describing it bythe safest, easiest and most efficient way.- contrary to the standardized work chartand work combination table relative to anoperator, this document is linked to aprocess or a basic operation from theprocess.
Standard Operation SheetImportant Safety issue: to be used if a real risk Whole Time neederemarks can exists for employees ! Standardized Combe written in STANDARD OPERATION FA U-F-PS-241 / EN version 02 Plant : Washington Document N o.: Rev ision Lev el: xxxx 4bold or Part Number xxx Part Name Bolster Line : EQ Bolster Work- station: Woodstock Page No: 1/1underlined No. Operation = SAFETY = QUALITY = TIP Time: 30 Sec Sketches / Photos / etc. 4 1 Remove cavities 3 & 4 from the mould tool. Remove parts from tool Place parts onto left side of bench (Fig1) Spiking frame big font Remove the spiking Remove the waste then place the frame onto the bench Cavitiesenables 2 frame from the upper Ensure frame handle is pointing away from you and spikes are pointing upwards. 1 4 Cavities 1 3 2 2 tool Fig 1.operator to 3read from Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to push 3 onto to stand. the existing waste into the granulator (fig 2).worstation Self-Quality check Granulator Remove the spiked Remove the spiked frame from underneath the bench place it into the guides on the Cooling stand upper mould tool (fig 1) 4 frame from the"Alt+Enter" underneath bench Ensure that the handle is pointing towards you is fully located against the censor Fig 2. White 5to go on the - Take one white & green LH clip from the dispenser.next line in 5 Place one white & green - Place the green clip into the center clip position and the white into the bottom location on cavity 4. clip into cavities 3&4 - Take one white & green RH clip from the dispencer.the same - Place the green clip into the center cl Green Whitecell Issued Signat ure/ Dat e Checked Signat ure/ Dat e Approved Signat ure/ Dat e SKILLED Signat ure/ Dat e Fig 3. N on C onforming Product: Name: Name: Name: OPERAT OR P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito r Function: Function: Function: Name: Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader.Tip : put thestress on Operator who participated Non-Comformanciesspecial in setting up the Standard Reaction rules have tocomments Operation be adapted to the workstation
Standard Operation Sheet Document No.: xxxx STANDARD OPERATION FAU-F-PS-241 / EN version 02 Plant : Washington Rev ision Lev el: 4 Part Work- Page Number xxx Part Name Bolster Line : EQ Bolster station: Woodstock No: 1/1 Time: No. Operation = SAFETY = QUALITY = TIP 30 Sec Sketches / Photos / etc. Remove cavities 3 & 4 from the mould tool. 4 1 Remove parts from tool Place parts onto left side of bench (Fig1) Spiking frame Remove the spiking Remove the waste then place the frame onto the bench Cavities 2 frame from the upper Ensure frame handle is pointing away from you and spikes are pointing upwards. 1 4 Cavities 1 3 2 2 tool Fig 1. 3 Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to push 3 onto to stand. the existing waste into the granulator (fig 2). Granulator Remove the spiked Remove the spiked frame from underneath the bench place it into the guides on the Cooling stand upper mould tool (fig 1) 4 frame from the underneath bench Ensure that the handle is pointing towards you is fully located against the censor Fig 2. White 5 - Take one white & green LH clip from the dispenser. Place one white & green - Place the green clip into the center clip position and the white into the bottom location on 5 clip into cavities 3&4 cavity 4. - Take one white & green RH clip from the dispencer. - Place the green clip into the center cl Green White Fig 3. Issued Signat ure/ Dat e Checked Signat ure/ Dat e Approved Signat ure/ Dat e SKILLED Signat ure/ Dat e Non Conforming Product:Name: Name: Name: OPERATOR P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito rFunction: Function: Function: Name: Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader.