kanban or pull production system
TRANSCRIPT
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Sreejith Bhattathiri MFM-798
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The Pull System Material is pulled through the system when
needed
Reversal of traditional push system wherematerial is pushed according to a schedule
Forces cooperation
Prevent over and underproduction
While push systems rely on a predeterminedschedule, pull systems rely on customer
requests
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Japanese word for card
Heart of JIT System
Scheduling system that can immediately and
clearly communicate demands of customer tothe delivery system
Authorizes production from downstream
operations Pulls material through plant
May be a card, flag, verbal signal etc.
Kanban Production Control System
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Used often with fixed-size containers Add or remove containers to change production rate
Kanban card indicates standard quantity of
production
Derived from two-bin inventory system
Kanban maintains discipline of pull production
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Level production (balance the schedule) in orderto achieve low variability of the number of partsfrom one time period to the next.
Avoid complex information and hierarchicalcontrol systems on a factory floor.
Do not withdraw parts without a Kanban.
Withdraw only the parts needed at each stage. Do not send defective parts to the succeeding
stages.
Produce the exact quantity of parts withdrawn.
Need of Kanban
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Visibility function
The information and material flow are combinedtogether as Kanbans move with their parts (work-inprogress).
Production function
The Kanban detached from the succeeding stage
fulfils a production control function which indicates
the time, quantity, and the part types to be produced.
Functions of Kanban
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Inventory function
The number of Kanbans actually measures the amountof inventory. Hence, controlling the number of Kanbansis equivalent to controlling the amount of inventory.
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Supplying
Process
Customer
Process
product
Production Card
Finished Goods
Store
Withdrawal Card
product
Kanban System
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A Sample Kanban
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Fabrication Area
Supply/Storage Area
Assembly AreaReceiverPost
Productionorder Post
P.O.
P.O.
P.O.
W.C.
KANBAN SEQUENCE
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ReceiverPost
Productionorder Post
W.C.
1. An assembly worker gets a Withdrawal Kanban from the receiver post thattells how many of each item to withdraw from Supply/Storage.
Fabrication Area
Supply/Storage Area
Assembly Area
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ReceiverPost
Productionorder Post
P.O.
W.C.
2. The assembly worker goes to the supply point and gets a cart with all the itemsspecified on the withdrawal card.
Fabrication Area
Supply/Storage Area
Assembly Area
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ReceiverPost
Productionorder Post
P.O.
3. There is a Production Order card on the cart that the assembly worker removes andplaces on the receiver post where someone from fabrication will get it.
W.C.
Fabrication Area
Supply/Storage Area
Assembly Area
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ReceiverPost
Productionorder Post
P.O.
4. The assembly worker places the withdrawal kanban on the full cart and takes itback to the assembly area to assemble.
W.C.
Fabrication Area
Supply/Storage Area
Assembly Area
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ReceiverPost
Productionorder Post
P.O.
5. Someone periodically removes the production order kanbans from the receiver post,reviews and sorts them for priority, and places them on the production-order post.
P.O.
Fabrication Area
Supply/Storage Area
Assembly Area
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ReceiverPost
Productionorder Post
6. A fabrication worker comes to the Production-Order Post and gets aproduction-order kanban and an empty cart.
P.O.
Fabrication Area
Supply/Storage Area
Assembly Area
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ReceiverPost
Productionorder Post
P.O.
7. Fabrication produces the items specified on the Production-Order Kanbandelivers them to the supply/storage area.
Fabrication Area
Supply/Storage Area
Assembly Area
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Primary Kanban: Travels from one stage to another among main
manufacturing cells or production preparation areas.
The primary Kanbans are two kinds, one of which is called`withdrawal Kanban (conveyor Kanban) that is carriedwhen going from one stage to the preceding stage.
The other one is called `production Kanban and is used toorder production of the portion withdrawn by the
succeeding stage.
Types of Kanban
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Supply Kanban: travels from a warehouse or storagefacility to a manufacturing facility
Procurement Kanban: travels from outside of acompany to the receiving area.
Subcontract Kanban: travels between subcontractingunits.
Auxiliary Kanban: may take the form of an express
Kanban, emergency Kanban, or a Kanban for a specialapplication.
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N = DT/C
Where n = total number of containers
D = Demand rate of the using work centre
C = container size in number of parts, usuallyless than 10 per cent of daily demand
T= time for a container to complete an entire
circuit (lead time)
Calculation of Number of Containers
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The Kanban system works well in repetitiveproduction environments (Line flows/product
focused) Ifyou are able to achieve small lot sizes and short set-up
times, and
Ifyour suppliers are close by and can make frequent
deliveries using a just-in-time system.
Kanban Use
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Reduce inventory level
Less confusion over sequence of activities
Less obsolescence of inventories while in storage
Smaller floor space requirements for storing inventory
Reduce lead time
Improved quality
Higher employee productivity
Greater system flexibility
Benefits
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