1. Elastic adaptability in production–Service Kanban, i.e. self-regulating, adaptive network of thousands of employees
Istvan Fekete
(fekete.istvan.pic@gmail.com)
Nokia 2009-2011

2. Service kanban
•Simple rules creating complex, adaptive behavior in network of 1000-2000 people in a production shift.
•Planned frames to create automatic escalation and adaptation
–10-15 Minutes
–Only 3 Service Cards
–Only 5 Cell Cards
–Only 2 Hooks, etc.
•While flexible behavior returns the system to original equilibrium, elastic behavior leads to adaptation to changes and to new equilibrium

3. Products grouppedinblocks with dedicated cells, while flex cells provide machine elasticity
One or more but similar products in one cluster
Cells dedicated to given cluster on daily level. Changeovers are planned accordingly
Dedication for stability
Elasticity Pool
Non-dedicated, flex cells at the end of echstreet allow quick supply grow without disrupting the operations

4. Services adapt to changing demand, pulled by andonlamps and flags and controlled by service kanbans
Each street (group of cells) has an owner of that service. Ownerswatch cell andons
Service Leader watches Main Street andonsand helps in the overloaded street
Main Street
Utca
Street
•Cell Operator calls the service with andonlamp and service flag
•Yellow andongives 10-15 minutes window for service provider to deliver
•Red andonmeans immediate delivery requirement
•Red andonalso calls the Cell Leader and Service Leader
•Flag color and symbol identify the required service
•Service Owner is for given street or group of cells
•Goes to cell of flashing andonand startsthe service
•Service Leader
•Helps in overloaded street or allocates more resource (gembaapproach)
Street
Street
Street
Street
Street
Street
Service Owner
Service Leader

5. Each service has its own color and symbol code consistently appearing everywhere
•Coat/Armband marking seen from distance (7*7 cm)
•The Flags in the cell under Andon lamp (15*20 cm)
•The big Flags in the main street under big Andon lamp (20*30 cm)
•If Service Owner can’t fulfill the demand immediately then there is an exchange of cards:
•Service owner leaves 1 of his Service Cards (3 per owner), i.e. Who owes to cell?
•Service owner takes 1 of the Cell cards (5 cell cards per cell), i.e. Which cell I owe?
•Service owners hand over theservice at shift changein situ
Armband
Maualimputin Line stop Report
Flags in the Cell
Service kanbancards
Flags in the Main Street

6. Flag 2
Flag 1
Red and Yellow andonlamps in the front of the cell and 2 pairs of hooks for 2 flags only
Immediate service required, otherwise the cell stops/thecellhas already stopped.
In 10-15 Minutes the service required, otherwise the cell will stop.
Ifmore than 2 services are pending, i.e. cell is in risky state

7. TT
A
Q
K
SP
T
NEM TERVEZETTÁLLÁS
SZÜNET
Product Technician
Quality Operator
1st Sales Pack to check
Non-planned brake
Material Handler
Finished Goods Shipping Operator
Maintenance Technician
Brake
Service Kanban Flag/Cardexamplesfromreallife

8. Andon Lamp Red & Yellow
Hook for 2 Flags
Flag holder
Andon Lamp Buttons Red & Yellow
Service Kanban Cards
Online RepairKanban Cards
Hook for 2 Flags
Examplesfromreallife

9. Service Kanban Cards (5/5)
Online RepairKanban Cards (6/6)
Secondary Card of Cell Operators
Material Handler (Blue) exchanges her Cardwith Cell Card to go and doing offline part of her service ASAP
Examples from real life

10. Service Kanban Process (Doers’ view)
Production Cell/Line
Service Provider
Production Runs
Service needs in 15 min.?
No
Switch on Yellow Andon and hook Service Flag on
Provide your service in max 10 minutes and check your Andonsregularily
Yes
Is there flashing Yellow Andon with my Flag?
Go to cell in 10 minutes and clarify the service need with cell colleague
Can I serve immediately?
1
1
No
Take off your Flag and switch off the Andon (if only your flag was on)
Go and fulfill offline part of your service and return to Cell
Is there flashing Red Andon with my Flag?
Go to cell within 1 minute and clarify the service need with cell colleague
Yes
No
2
Yes
Yes
Has Cell stopped due to my service need?
Yes
No
No
Production Runs
Service needs now?
No
Switch on Red Andon and hook Service Flag on
Yes
2
Take off your Flag and switch off the Andon (if only your flag was on)
Take 1 Cell Card and put 1 of your Kanban Card to Cell Board
Take 1 Cell Card and put 1 of your Kanban Card to Cell Board
Urgently fulfill offline part of your service, return to Cell and finish your work
Take of your Flag and switch of the Andon (if only your flag was on)

11. Service Kanban Process (Leader’s view)
Production Cell/Line
Cell/Line Team Leader/Service Team Leader
Walk around and check the status of the Cells through Andonsand Flags
Are there flashing Yellow Andonswith same/myFlag?
Go to cells ASAP and evaluate the risk of overload in service
Is the Service Provider there?
1
No
Thank the perfect work for both cell personelland service provider
Discuss the line stop with your Team Leader party in 15 minutes
Is there flashing Red Andon (/with my Flag)?
Go to cell within 1 minute and clarify the service need with cell colleague
Yes
No
2
Yes
Yes
Has Cell stopped due to that service need?
Yes
No
No
Find the person and help him/her to act
Consider process audit at cell
Production Runs
Service needs in 15 min.?
No
Switch on Yellow Andon and hook Service Flag on
Yes
1
Production Runs
Service needs now?
No
Switch on Red Andon and hook Service Flag on
Yes
2
Discuss the risk with your customer party in 15 minutes

12. Service Kanban Process (Escalation)
Service Provider
Service Team Leader
Walk around and check the status of the Streets through Andonsand Flags
Is the Service Provider there?
Consult with him/her
Discuss the overload with Cell/Line Team Leader party in 15 minutes
Is there flashing Big Red Andon with my Flag?
Go to overloaded Street within 1 minute and clarify the issue
Yes
No
3
Yes
No
Find the person ASAP
Do my service
Am I overloaded?
No
Switch Big Red Andon onand hook Big Service Flag on in the Main Street
Yes
3
Decide on help, additional service allocation and act immediately