Kanban

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The Kanban system

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Kanban

  1. 1. 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
  2. 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
  3. 3. 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
  4. 4. 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
  5. 5. 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
  6. 6. 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
  7. 7. 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
  8. 8. The Kanban System Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. <ul><li>Each container must have a card </li></ul><ul><li>Assembly always withdraws from fabrication (pull system) </li></ul><ul><li>Containers cannot be moved without a kanban </li></ul><ul><li>Containers should contain the same number of parts </li></ul><ul><li>Only good parts are passed along </li></ul><ul><li>Production should not exceed authorization </li></ul>KANBAN Part Number: 1234567Z Location: Aisle 5 Bin 47 Lot Quantity: 6 Supplier: WS 83 Customer: WS 116
  9. 9. Number of Containers <ul><li>Two determinations </li></ul>Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. <ul><li>Number of units to be held by each container </li></ul><ul><ul><li>Determines lot size </li></ul></ul><ul><li>Number of containers </li></ul><ul><ul><li>Estimate the average lead time needed to produce a container of parts </li></ul></ul><ul><li>Little’s law </li></ul><ul><ul><li>Average work-in-process inventory equals the average demand rate multiplied by the average time a unit spends in the manufacturing process </li></ul></ul>
  10. 10. 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
  11. 11. Number of Containers <ul><li>Formula for the number of containers </li></ul>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
  12. 12. Other Kanban Signals <ul><li>Cards are not the only way to signal need </li></ul><ul><li>Container system </li></ul><ul><li>Containerless system </li></ul>Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall.

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