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The Kanban system

The Kanban system

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Kanban Kanban Presentation Transcript

  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Figure 8.4 – Single-Card Kanban System Receiving post Kanban card for product 1 Kanban card for product 2 Fabrication cell O 1 O 2 O 3 O 2 Storage area Empty containers Full containers Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Storage area Empty containers Full containers Receiving post Kanban card for product 1 Kanban card for product 2 Figure 8.4 – Single-Card Kanban System Fabrication cell O 1 O 2 O 3 O 2 Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Storage area Empty containers Full containers Receiving post Kanban card for product 1 Kanban card for product 2 Figure 8.4 – Single-Card Kanban System Fabrication cell O 1 O 2 O 3 O 2 Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Storage area Empty containers Full containers Receiving post Kanban card for product 1 Kanban card for product 2 Figure 8.4 – Single-Card Kanban System Fabrication cell O 1 O 2 O 3 O 2 Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Storage area Empty containers Full containers Receiving post Kanban card for product 1 Kanban card for product 2 Figure 8.4 – Single-Card Kanban System Fabrication cell O 1 O 2 O 3 O 2 Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Storage area Empty containers Full containers Receiving post Kanban card for product 1 Kanban card for product 2 Figure 8.4 – Single-Card Kanban System Fabrication cell O 1 O 2 O 3 O 2 Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. Storage area Empty containers Full containers Receiving post Kanban card for product 1 Kanban card for product 2 Figure 8.4 – Single-Card Kanban System Fabrication cell O 1 O 2 O 3 O 2 Assembly line 1 Assembly line 2
  • The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall.
    • Each container must have a card
    • Assembly always withdraws from fabrication (pull system)
    • Containers cannot be moved without a kanban
    • Containers should contain the same number of parts
    • Only good parts are passed along
    • Production should not exceed authorization
    KANBAN Part Number: 1234567Z Location: Aisle 5 Bin 47 Lot Quantity: 6 Supplier: WS 83 Customer: WS 116
  • Number of Containers
    • Two determinations
    Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall.
    • Number of units to be held by each container
      • Determines lot size
    • Number of containers
      • Estimate the average lead time needed to produce a container of parts
    • Little’s law
      • Average work-in-process inventory equals the average demand rate multiplied by the average time a unit spends in the manufacturing process
  • Number of Containers Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. WIP = (average demand rate)  (average time a container spends in the manufacturing process) + safety stock WIP = kc kc = d ( w + p )(1 + α ) k = d ( w + p )(1 + α ) c where k = number of containers d = expected daily demand for the part w = average waiting time p = average processing time c = number of units in each container α = policy variable
  • Number of Containers
    • Formula for the number of containers
    Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. WIP = (average demand rate)(average time a container spends in the manufacturing process) + safety stock k = Average demand during lead time + Safety stock Number of units per container
  • Other Kanban Signals
    • Cards are not the only way to signal need
    • Container system
    • Containerless system
    Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall.