This document discusses Pull Systems and Kanban Cards. It provides an overview of Pull vs Push inventory systems, explaining that Pull Systems like Kanban only produce or replenish inventory based on actual customer demand, leading to less excess inventory compared to Push Systems. Kanban uses visual cards to signal when more inventory is needed to "pull" production or replenishment. The document outlines the basics of the Kanban system and card usage, including examples of different card types and ground rules for effective Kanban implementation. It concludes with the "Family Milk Story" to summarize the key points.
This project gives an introduction to the history and philosophy behind lean management, including just-in-time (JIT) manufacturing, push & pull scheduling, kanban system and continuous improvement process.
Submitted by: Gaurav Singh, Parmeet Singh, Pragya Sarin, Pratistha Gupta, Sanyam Khetarpal, Satya Mathur
Subject: Operations Management, Year: 2015-16
Course: Bachelors of Management Studies
College: Shaheed Sukhdev College of Business Studies, University of Delhi
All rights reserved.
In all reality, there are the production waste. Here I explain the 7 wastes from most towns elliminare. Based on the TPM and Lean Management.
For info please contact me.
This project gives an introduction to the history and philosophy behind lean management, including just-in-time (JIT) manufacturing, push & pull scheduling, kanban system and continuous improvement process.
Submitted by: Gaurav Singh, Parmeet Singh, Pragya Sarin, Pratistha Gupta, Sanyam Khetarpal, Satya Mathur
Subject: Operations Management, Year: 2015-16
Course: Bachelors of Management Studies
College: Shaheed Sukhdev College of Business Studies, University of Delhi
All rights reserved.
In all reality, there are the production waste. Here I explain the 7 wastes from most towns elliminare. Based on the TPM and Lean Management.
For info please contact me.
Lean manufacturing is a production process based on an ideology of maximising productivity while simultaneously minimising waste within a manufacturing operation
However, Muda is not the only ‘M’ Toyota has built its famous Toyota Production System around, there are two more: Mura (Variation) and Muri(Overburden).
Thanks@Regards,
Call - 08510001499,
E-Mail - training@ignite2shine.com
Visit: ignite2shine.com
This PPT defines what is lean manufacturing , its history , and its application.
It also covers how we could apply lean manufacturing in our daily lives.
POKA-YOKE - A Lean Strategy to Mistake ProofingTimothy Wooi
A Lean Strategy in Human Error Prevention aims to detect and correct possible error immediately, eliminating defects at the source.
Poka-Yoke overcome the inefficiencies of inspection through the use of automatic devices that seek,
1.Not to accept a defect for the process
2.Not to Create a Defect
3.Not to Allow a Defect to be passed to the next process
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalized, and the term adopted, by Shigeo Shingo as part of the
Toyota Production System.
It was originally described as baka-yoke, meaning "fool-proofing“ or “idiot proofing” but the name was later changed to the milder poka-yoke.
Production Line OEE (Overall Equipment Effectiveness)Brian Thomas
This webinar session reviews utilizing a proven, lean manufacturing technique, called Overall Equipment Effectiveness, or OEE for short. DST Controls discusses what OEE is and why it is so important for modern manufactures to incorporate it in their operations. Barry Callebaut, a major chocolate producer, had no visibility into their process to determine if the proper amount of ingredients were used in their batch process. An OEE solution by Rockwell Automation was implemented to automatically track material loss, and company estimates they have achieved a $500k net annual gain through resultant ingredient optimization and product consistency.
Lean manufacturing is a production process based on an ideology of maximising productivity while simultaneously minimising waste within a manufacturing operation
However, Muda is not the only ‘M’ Toyota has built its famous Toyota Production System around, there are two more: Mura (Variation) and Muri(Overburden).
Thanks@Regards,
Call - 08510001499,
E-Mail - training@ignite2shine.com
Visit: ignite2shine.com
This PPT defines what is lean manufacturing , its history , and its application.
It also covers how we could apply lean manufacturing in our daily lives.
POKA-YOKE - A Lean Strategy to Mistake ProofingTimothy Wooi
A Lean Strategy in Human Error Prevention aims to detect and correct possible error immediately, eliminating defects at the source.
Poka-Yoke overcome the inefficiencies of inspection through the use of automatic devices that seek,
1.Not to accept a defect for the process
2.Not to Create a Defect
3.Not to Allow a Defect to be passed to the next process
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalized, and the term adopted, by Shigeo Shingo as part of the
Toyota Production System.
It was originally described as baka-yoke, meaning "fool-proofing“ or “idiot proofing” but the name was later changed to the milder poka-yoke.
Production Line OEE (Overall Equipment Effectiveness)Brian Thomas
This webinar session reviews utilizing a proven, lean manufacturing technique, called Overall Equipment Effectiveness, or OEE for short. DST Controls discusses what OEE is and why it is so important for modern manufactures to incorporate it in their operations. Barry Callebaut, a major chocolate producer, had no visibility into their process to determine if the proper amount of ingredients were used in their batch process. An OEE solution by Rockwell Automation was implemented to automatically track material loss, and company estimates they have achieved a $500k net annual gain through resultant ingredient optimization and product consistency.
This file introduces the principle of Kanban and pull system. In the rest of the file, we concentrate on Kanban and introduce the types of Kanban, six rules for an effective kanban system, the number of Kanban card and kanban circulation.
Literally, Kanban is a Japanese word that means "visual card". At Toyota, Kanban is the term used for the visual & physical signaling system that ties together the whole Lean Production system. Kanban as used in Lean Production is over a half century old. It is being adopted newly to some disciplines as software.
Overview on Kanban Methodology and its ImplementationLaukik Raut
Kanban methodology is very significant
philosophy which plays an important role in many
production units. In this paper Kanban methodology has
been reviewed and has been implemented on „Swing Lever
Assembly‟ of the Bajaj Steels Pvt. Ltd Nagpur. The Kanban
system involves the selection of two important parameters
i.e. the lot size and the numbers of Kanban used in the
process. The main objective of Kanban system is to
maximize the productivity of a unit and this is done by
reducing the idle time of the process. Kanban system is a
very cost efficient process if applied in proper manner.
1. Pull System & Kanban Cards
a Tool of Lean Manufacturing
2. CAS Medical System’s
Route to World Class Manufacturing
Minimum
6 Investment
Lean Sigma
Building Tools
Value Stream 5s Flexible Small Lot Rapid Response
TQM
Mapping Evaluation Work Force Production to Change
Waste
Layout Visual Setup One Piece Short Cycle Highest
Elimination
Changes Controls Reductions Flow Manufacturing Quality
(Muda)
Standard Pull
Suggestion Quick
Work Takt Time Systems Kaizen
Program Delivery
Instructions (Kanban)
TPM
Best Process
Reliability
3. Push vs. Pull Inventory Systems
Push – Whether you need it or not you’re getting
it anyway. (Old school)
Sales Customer
Forecast→Purchasing→Supplier→Stock→Production→Demand
100 → 100 → 100 → 100 → 100 → 10
* Based on the customers demand you have 90% excess inventory
4. Push vs. Pull Inventory Systems
Pull – You get it only when you ask for it.
(New school)
Cust. Demand → Production → Stock → Purchasing → Supplier
10 → 10 → 20 → 10 → 10
(2KB@10ea)
* Based on the customers demand you have 50% excess inventory,
but you have 40% less inventory compared to the Push system.
5. Pull Systems are:
Simple and Visual
Executed by shop floor employees
Runs on customer demand rates
Push Systems are:
Complex
Executed by Production Control &
Purchasing
Runs on forecasted dates & sales history
6. Types of Pull Signals
Kanban Cards
Electric Lights
Standard containers
Painted or taped squares on the floor
Level Indicator Signs
7. Kanban Card
Is considered to be the best Pull Signal
system you can use to control your inventory
dollars, prevent part shortages and improve
your cash flow.
8. So what is Kanban?
Kanban is a Japanese word that means “card”
It was originated by Japan’s Toyota Co.
It is a tool of lean manufacturing that’s used to apply JIT
(Just In time) inventory.
It is a type of reorder point system.
It is not a zero inventory system
It is a manual technique that is in the hands & controlled
by the production workers.
9. Keys to a successful Kanban system
It’s not the cards themselves, but the
discipline performed by the employees
Material is not moved or produced without
Kanban cards
The emphasis is not to balance capacity, but
to balance flow
12. Made To Order Kanban Card
P/N: 01-02-0406
750E-2NL VA MONITOR ETXT WA
SUB # 03-08-0619
1-KANBAN (MTO)
QTY: _____________________
DUE:______________________
13. Today’s Purchasing Card
PURCHASING INVENTORY KANBAN CARD
P/N: 28-02-0122 Buyer Code: 01
Description: Foam Pad 2 x ¼”
Used On: 511’s
# of KB Cards: 1
Reorder Point: 25
Reorder Qty: 100
Date Ordered: Vendor: EAR Specialty
Lead Time: 42 days Vendor#:
Delivery Date: Notes:
**Issue to Work Center:
14. What 2 items are missing on this Internal work cell
Kanban card?
STOCK TRANSFER CARD
PART NUMBER: 28-02-0422
DESCRIPTION: FOOT PAD
REORDER QTY-PCS: 60
DELIVER TO CELL: 740 / 750
STOCK LOCATION:
1)Reorder point quantity
2) # of Kanban cards
15. Kanban Card Ground Rules 1 - 5
1) Operators can change KB card quantities as demand increases or
decreases.
2) In a 2 bin card system, complete 1 bin first before going into the
2nd bin. Don’t double dip.
3) Putting both KB cards into 1 bin to save space is OK, but you will
have to manually monitor your actual counts so you know when to
hand in the first card for replenishment
4) KB quantities for large parts that utilize a lot of space should be set
to a 1 day’s supply. Small parts should not exceed more then a
weeks usage.
5) Change piece quantity on some cards to number of boxes. This
will save you space and will save the stock person time in issuing.
16. Kanban Card Ground Rules 6-10
6) We should never see empty bins w/ KB cards in them; Never see
KB cards lying on an empty shelf; Never see KB cards lying on the
floor; Never see KB cards unattached to materials.
7) Lost KB cards will happen. Make sure you report it so a new card
can be made ASAP.
8) Determine ways to attach KB cards to materials to prevent them
from getting lost & misplaced. (zip-lock bags, scotch tape,
magnetic clips, paper clips, adhesive pouches)
9) Stock person & cell operators must make sure that KB cards are
placed in proper positioning for timely replenishment from stock.
10) Keep KB cards with the item. Don’t keep them hidden in folders,
drawers, etc. They should be visual.