The document discusses the implementation of a Kanban system at KSSB. It provides details on: 1. The phased implementation of Kanban at different production lines from April 2006 to November 2006. 2. The basic 7 steps to implement Kanban including data collection, calculating bin size, designing bins, training, starting Kanban on lines, auditing, and continuing improvement. 3. Key aspects of the Kanban system including using average daily consumption to set bin quantities, using 2-3 bins per line position with barcoded labels, and empty bins triggering new orders.

1. KSSB Kanban

2. KSSB Kanban
Implementation:
• KS4_90 : April 2006
• KS6_90 : July 2006
• KS5_90 : September 2006
• KS3_90 : November 2006
• KS7_90 : November 2006
• Cutting, KS1_90 & KS2_90 : Due to a space
constraint, a brainstorm meeting will take place
beginning 2007.

3. KSSB Kanban
Implementing Kanban
(Seven basic steps to implement Kanban)
1. Conduct data collection
2. Calculate the Kanban size (bin, qty)
3. Design the Kanban
4. Training
5. Start of Kanban on the line
6. Audit the Kanban Process
7. Lessons learned/ Continues Improvement

4. KSSB Kanban
Basic Concept:
• Kanban basic data is based on the average daily
consumption of two weeks.
• 2-3 bins of a part/position per line. This should be 3 days
production stock. Rotation time of bins needs to be
calculated.
• Each bin will have a label with the ident number, Line,
Line Position, Quantity and Barcode(Kanban order).
• Empty bins will be send back to the store to be scanned
and thus will create the next Kanban order for the line.
• KS1_90, KS2_90 and cutting are running on a manual on-
line ordering system until Kanban is implemented.

5. KSSB Kanban
KS4_90 7409Eur 2674 Euro -4735Eur
KS5_90 5699Eur 4223Eur -1476Eur
KS6_90 3691Eur 3160Eur -531Eur
KS7_90 4469Eur 1568Eur -2901Eur
KS3_90 18570Eur 15103Eur -3467Eur
Total stock
saving
-13110Eur
Production Line
SOH value before
Kanban
SOH value after
Kanban Difference
SOH Value reduction

6. KSSB Kanban
Lessons Learned / Continues Improvements
Full Kanban process not
followed by all operators.
Lack of training and
understanding. Absent
compensators not following the
process.
Training Department to complete
training on the lines and all
operators to write a test to ensure
Kanban understanding. Set-
compilers to rotate on a weekly
basis to ensure part & position
knowledge of all lines.
Empty bins not scanned in
time/ lost
Labels falling off, bins taken out
for cleaning without scanning
Online scanners to be
implemented. Set-compiler to
scan bin on line. Clean bins must
be used at all times.
Hand written labels on the bins Labels falling off and replaced
by hand written labels.
Lost labels must be reported to
the Kanban co-ordinator and be
reprinted.
Using more than one bin at a
time on the line.
Shelf space constraint on the
taping side.
Two bins to be placed on top of
each other, bottom one to he
facing to the back.
Problem Reason Solution

7. KSSB Kanban
Lessons Learn / Continues Improvements
Booking error Material show on scanner
booked, but don’t book from
system
IT to look at program error and
possibility of printed
confirmation sheets. Operator to
make sure that all material is
booked from scanner.
Manual bookings Manual Kanban requisition must
be booked off by a data capturer.
IT to look into possibility of
booking manual Kanban
requisitions directly from the
system as per normal Kanban
orders.
Problem Reason Solution

8. KSSB Kanban
Future Investments:
• Extra scanners and terminals for production lines.
Scanning to be possible directly from production line.
• Trolleys to collect and return empty bins from the
production lines. (Milk-run - KSSK)
• Improvement on the Kanban shelves
• Headcount : Time studies to be done to proof the speed of
the system. From result of the time studies, warehouse
headcount need to be adjusted.

9. POSITIVE AND NEGATIVE FEEDBACK
NEGATIVE FEEDBACK
• All set compliers as well as the
operators on the line needs to receive
intensive training. One trainee must
be 100% utilized for this.
• Why:Because of the new system
being implemented everyone needs
to receive the required knowledge
and know how.
• When:HR is currently implementing
the new Kanban training process
• Bins receives without labels
• Two of the same indents are returns
to the warehouse
• Urgent stock requirements daily
• Line requirements exceed the amount
on certain indents.
• Manual capturing needs to be done
on manual Kanban requisitions.
POSITIVE FEEDBACK
• The system eliminates paperwork
• It reduce the margin of human error
• It’s easier and more effective way of issuing
stock for operators
• From line they get there stock much faster
than in the past.
• It reduces move and Queue time in front of the
issuing gate.
• Reduce the number of operators calling on the
warehouse for stock
• Currently training is given by the Kanban co-
coordinator and the shift supervisors on duty.
Training to assist 100% till all operators
understand the function of Kanban.
• Operators use a push instead of a pull system.

10. KANBAN FLOWDIAGRAM
Warehouse
Shelves
with bins
Building boards
Full kanban
bin
In process storage
Empty
bins
Empty bins

11. Before Kanban
Shelve over full with bins
To much material in bins
Production line looks untidy with all this bins

12. After Kanban
Less material in bins Production line appears more need with Kanban

13. Barcode label: Ident,Preset QTY, & line
Shelve with stock
Need and clean shelves with kanban qty No more overfull shelves

14. Operators working on the new kanban system