Kanban Explained in 11 Slides

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Kanban explained - both for manufacturing processes as well as non-manufacturing: service, project management, etc. Kanban really isn't as complicated of a concept as people make it out to be. It's pretty much all one model applied in different ways.

This presentation has some theory, some examples, and some advice & quotes related to the tool

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Kanban Explained in 11 Slides

  1. 1. Kanban Explained (includes other processes besides picking component parts) Kanban (“KAHN-BAHN”) – Japanese word meaning “signboard or billboard” – a scheduling system to ensure that only what is needed is produced
  2. 2. The general idea of Kanban 2. Supplier pulls the order info to produce to the order Supplier 1. Customer logs an order in an order system Order Information Customer 3. Supplier delivers exactly what the customer ordered Each action is triggered by the delivery of the order itself, requiring less effort to manage the information and timing of tasks
  3. 3. Some different Kanban methods Central information spot • “Kanban Board” – physical board showing order status • SharePoint Task List (tasks are “orders”) Physical movement of a bin or card • Empty, labeled bin physically delivered to the supplier • Card with order information delivered to supplier
  4. 4. Example: Picking large sheet metal parts with forklift (at Kirby Risk Service Center) 2. Forklift driver picks the part, and applies a label to it showing the KR Part # Forklift Driver 1. Parts picker writes up a sheet metal pick ticket Parts Picking Card Parts picker Wow, sure glad I can drive this forklift… WITH MY MIND 3. Forklift driver delivers part to job staging area
  5. 5. Example: Kanban project board What it looks like: Done 2. Task owner moves post-it into “In Process”, and works on task LARRY MOE CURLY Backlog In Process 1. Project manager puts task postit onto “Backlog” section of Kanban board Task owner Kanban Board Task Assigner = regular task = hot task 3. Task owner moves post-it to “done” (and notifies project manager, if it is hot) 4. Team meets in regular accountability meeting to… • • • Discuss issues (interruptions, barriers to flow, etc.) Problem solve together Plan further action
  6. 6. Kanban Project Board, ctd. Close-up view of the board LARRY MOE CURLY Backlog In Process Done Color Code = regular task = hot task
  7. 7. Example: SharePoint Task List 1. Task manager creates task in SharePoint list 2. Task owner marks task as “In Process” Task owner SharePoint Task List 3. Task owner marks task as “Complete” Task Manager 4. Task manager notified
  8. 8. How to make an electronic Kanban system actually work…make it visual! In electronic systems, tasks can tend to get hidden in the sea of electronic inventory: folders, websites, spreadsheets, databases, etc. Here are some ways to make it visual… 1. 2. 3. 4. Automatic email gets sent to task list manager when changes are made to a task Regular process for task owners & task manager to check task lists When a task owner marks a task as “in process”, they make a note which they visually display at their workstation Use dashboard(s) to draw together information from multiple info sources to a single place
  9. 9. Best Practices with physical Kanban bins • Three-bin system – A bin is kept at the initial demand point, the inventory control point, and at the supplier (bins have a removable card with product details and other needed information) • Calculate just enough Kanban cards for each product • Use a heijunka box: Regular time increments (ex: 30 min) Info from: http://en.wikipedia.org/wiki/Kanban http://en.wikipedia.org/wiki/Heijunka_box Products (a.k.a. load-leveling box)
  10. 10. Some rules used by Toyota 1. Do not send defective products to the subsequent process. 2. The subsequent process comes to withdraw only what is needed. 3. Produce only the exact quantity that was withdrawn by the subsequent process. 4. Level the production. 5. Kanban is a means of fine tuning. 6. Stabilize and rationalize the process. Info from http://en.wikipedia.org/wiki/Kanban
  11. 11. How Kanban helps with common problems Problem How Kanban helps Bottlenecks / Multitasking / Task-switching Helps process users to do one-piece-flow, which cuts down on WIP People stressed because too much is demanded on them Makes work visual, which naturally creates more accountability, and allows employees to better level out the work Communication breakdowns Manages the communication task itself, so there’s much lower risk of forgetting to notify the people who need updates Kanban is a great tool, but just like a hammer, there are times when it works well by itself to fix an obvious problem (ex: a nail sticking out of a cabinet), but there are times when a lot more than a hammer is needed (ex: improving on time delivery of cabinets). Kanban systems can help to improve the flow of information or products in a workcenter or team, but it is a tool that is best deployed aligned with a company-wide improvement program “Just using Lean tools is like looking after an animal for years without knowing if it was a dog, rabbit, leopard or a sick rat” –Author Stephen Parry
  12. 12. And now for something completely different… (Images from www.leanmemes.com)
  13. 13. About the author: Brent Brewington Quality Specialist Blog: Twitter: LinkedIn: About.me: QualityIdeasGuy.com twitter.com/BrentBrewington LinkedIn.com/in/BrentBrewington about.me/BrentBrewington You are more than welcome to connect with me and get in touch. I’d love to listen to your ideas, and to share some of mine How I found my way into quality: While managing a Korean/Japanese restaurant serving Purdue students, I started to lean up the order management, production, and service processes, and realized that I wanted to do that for a living: improving processes and systems so that they are easier for people to use, and increase in performance. After doing some soul-searching and intense networking, I landed a job in quality at a tier one supplier to Caterpillar, and haven’t looked back since!

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