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Kanban
 

Kanban

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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.