Kanban systems are a scheduling and inventory management method used in lean manufacturing. Some key points: - First developed at Toyota in 1953, kanban relies on inventory control cards or electronic signals to trigger production based on demand. - It uses a pull system where downstream demand pulls production from upstream processes, rather than pushing excess inventory. - Visual signals like cards in bins indicate when inventory is running low and needs replenishing to avoid over- or under-production.

1. KANBAN SYSTEMS
SHUBHAM
GUPTA
11bme1100
https://www.youtube.com/watch?v=ku5D9TqTvrc

2. • It’s a scheduling system for just in time production.
• First used in Toyota in 1953 in their machine shop.
• Kanban refers to the posting board (and the inventory control cards
posted there) where the evolution of the manufacturing process would
be recorded.
• The Kanban system is a manual information system that relies on various
types of inventory control cards.
• It’s development is closely tied to the development of SMED: Single
Minute Exchange of Dies, that allowed model changeovers to take place
in minutes rather than hours.
• The Fundamental Idea of JIT – and Lean Manufacturing Systems in
General (an Americanization of the Toyota P. S.) – is to empower the
workers to make decisions and eliminate waste wherever it is found
What is Kanban system?

3. How it works?
• Idea is similar to one used in supermarket
• A small stock of every item sits in a dedicated location
with a fixed space allocation
• Customers come to the store and visually select items
• An electronic signal goes to the supermarket's regional
warehouse detailing which items have sold
• The warehouse prepares a replenishment of the exact
items sold.
• Kanban uses the rate of demand to control the rate of
production, passing demand from the end customer up
through the chain of customer-store processes
• Also called a pull system as demand creates a supply.

4. Double sided racks.
Stacking bins, when top is empty, remove
and start using the bottom bin.
Variable size stackable
bins

5. Double sided racks

6. Special twinbins, top holds second
inventory, when bottom is empty, pull
middle lever that allows top inventory
to drop into lower bin, flag pops up
identifying upper bin needs to be
refilled.

7. Stacked supplyReserve supply behind

8. Principle
• It works on the principle of demand and not
forecast
• According to this system, A company should
not make large amounts of stock and then try
to sell it. Companies need to be aware of the
market place and what the customers wants.
• The pull system uses visuals to signal when
parts need to be replaced.

9. How is signaling done?
• Earlier cards (kanban in japanese) were used to
signal the demand for any product
• Nowadays electronic kanbans are used that use
sensors and computers.
• Eg: Bar code scanners upload sold items in
computer that gives signal to the warehouse

10. Positive Results
• Employees do not need to be assigned a job, they
are allowed to perform work when and where it is
needed.
• The skill level of employees is increased and the
variety gives them more satisfaction from their
work.
• Improves the accuracy of manufacturing
schedules

11. Advantages Disadvantages
JIT  PULL
Limited and known Final Inventory Every job is a ‘High Stress’ Rush
order
Unnecessary paperwork is eliminated
Workers effectively consume their time & Raw Materials
on what is actually needed
Balanced systems MUST be in place
Quality MUST be High – each piece has a definite place
to go – else immediate feedback is given
{error is less}
Setup times will greatly impact
throughput
Any problem will lead to unhappy
customers (either internal or
external)Enhances supplier/customer relationships

12. Focus on The Kanban
• Typically it is a 2-card system
• The P (production) Card and W (withdrawal) Card
• Limits on product inventory (number of P & W cards) are set
by management policy
• The count is gradually lowered until problems surface
• The actual target level (card count) is based on short term
forecasting of demands

13. Focus on The Kanban
• So how many cards? –
speaking of which, a
card is associated with a
container (lot) of
product so the number
of P & W cards at a
station determines the
inventory level of a
product!
is # of Kanbans
D is 'average' demand
L is lead time (proc+wait+travel+others)
w is buffer stock/ set by policy
typically 10% of DL
a is container cap. < 10% of daily demand
DL w
y
a
y



15. In the last few years, systems sending kanban signals
electronically have become more widespread. While
this trend is leading to a reduction in the use of
kanban cards in aggregate
In Oracle ERP (enterprise resource planning), kanban is
used for signaling demand to vendors through e-mail
notifications
A Red card lying in an empty parts cart conveys
that more parts are needed.

16. Three-bin system
One bin is on the factory floor (the initial demand point), one bin is
in the factory store (the inventory control point), and one bin is at
the supplier's business. The bins usually have a removable card
containing the product details and other relevant information — the
classic kanban card.

17. Just PlaY !!!!