principles of kanban - november 2016
TRANSCRIPT
Principles of Kanban Introduction
Thinking win, Win, WIN
Principles of KanbanIntroduction to Kanban
Marek Piatkowski – November 2016
Thinking win, Win, WIN
Principles of Kanban Introduction
Thinking win, Win, WIN
Introduction - Marek Piatkowski Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994
TPS/Lean Transformation Consulting - since 1994 Professional Affiliations
TWI Network – John Shook, Founder Lean Enterprise Institute (LEI) – Jim Womack Lean Enterprise Academy (LEA) – Daniel Jones CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
Principles of Kanban Introduction
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What is a Pull System?
Pull
Principles of Kanban Introduction
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TPS(Toyota Production System)
is born
Roots of Lean
1950 - 51
1951
Principles of Kanban Introduction
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M r. Ohno's Idea
Food M art
Supermarket
W areho use
Principles of Kanban Introduction
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Supermarket for Manufacturing
Principles of Kanban Introduction
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Food M art
Supermarket
S ignS tock ro om
The Superm arket M odel
Principles of Kanban Introduction
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The Superm arket Suppliers
Food M art
Supermarket
W arehouse
S u p p lie r S u p p lie r
S tock room
Principles of Kanban Introduction
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“Shopping” at a Supermarket No Purchased Order required No schedule of what I need and when Supermarkets are open 24/7 EVERYRYTHING is available – there are no shortages All Supermarkets (anywhere in the World) have a standard layout
Principles of Kanban Introduction
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Can Supermarket principles work in Manufacturing?
Principles of Kanban Introduction
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Pull System
In a traditional operation Production Scheduling department generates Information by issuing schedules to all departments to produce and to move material.
Toyota reversed that process. At Toyota only material movement generates Information Flow - A Pull Signal (Kanban).
When parts are “pulled” from the Supermarket, a signal (Kanban) is sent to the supplying process to produce more.
Schedule is issued only to the Pacemaker process. This is called a Pull System.
Principles of Kanban Introduction
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Kanban System and Kanban Cards Kanban System is a practical tool of Just-in-Time manufacturing for
controlling production (Production Kanban) and delivery of parts and materials (Delivery Kanban)
The word Kanban in Japanese means “signboard”. A Kanban card signals what to produce or to deliver necessary parts,
in necessary quantities, at the necessary time, in the most economical manner
What is needed When it is needed In the needed amount
We control levels of inventory through a use of Kanban Card We can easily tell what parts we have and what parts we need –
we do not waste time looking for parts
Principles of Kanban Introduction
Thinking win, Win, WIN
Kanban System Each process maintains a small supply of parts necessary to
produce a final product. Parts are stored in containers. The amount of parts per container
is usually small, pre-defined and always the same. A Kanban card is always placed inside or attached to a new
container. When there are only few parts left in a container a light signal is turned on and the Kanban card is placed in the Kanban post.
Within few minutes an assembly stock person responds to the signal and collects Kanban cards. These cards are treated as a signal to replace used up parts by either delivering a container of new parts from the parts storage to the linesite, or by producing new parts in a different location of the process.
Principles of Kanban Introduction
Thinking win, Win, WIN
Two Types of Kanban
KANBAN
1. ProductionKanban(what to produce)
2. DeliveryKanban(what to deliver)
In processKanban (flow)
InternalKanban (delivery)ExternalKanban (Supplier)
SignalKanban (batch)
Principles of Kanban Introduction
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Traditional Production Scheduling method
Results = Long lead times and poor efficiency
Warehouse
ProductionControl
Op. 1 Op. 2 Op. 3
WeeklySchedule Shipping
ScheduleWeeklySchedule
II I
WeeklySchedule
F act or y
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How is Kanban System operating?
Shipping
ProductionControl
Op. 1
Shipping Schedule
Fact or y
F I F O
Op. 3Op. 2
Kanaban Kanban
Result = Shorter lead times and higher efficiency
Principles of Kanban Introduction
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Production Kanban
KANBAN
1. ProductionKanban(what to produce)
2. DeliveryKanban(what to deliver)
In processKanban (flow)
InternalKanban (delivery)
ExternalKanban (Supplier)
SignalKanban (batch)
Principles of Kanban Introduction
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Production Planning Process
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What is Production Planning
Plan production in order to: balance Manpower, Materials and Machines produce correct volume, mix and sequence and make a product that meets the Customer Demand at the Lowest Total Cost and deliver the final product on time
Principles of Kanban Introduction
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Production Planning Challenges Forecast vs. actual Sales orders Changing Customer orders Quality problems Premium shipments Unplanned overtime effect on Supply Chain Overproduction Engineered vs. Demonstrated Capacity Planning and Leveling week to week Inventory fluctuation Executive Monthly Performance Review
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Planning based on Forecast (MRP)
Traditional method of scheduling production is to use the Sales Forecast to:
Order raw materials and purchased parts Schedule production on weekly basis
The problem with Forecasts is that: They are not accurate (50% - 70%) Customer demand changes all the time
This quite often results in: Long lead times Frequent schedule changes due to parts
shortages Overproduction
or
Customer Forecast
Shipping History
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Production Kanban System In the TPS (Toyota Production System), a unique production control
method called the “Kanban system" plays an integral role The Kanban system has also been called the "Supermarket
method" because the idea behind it was borrowed from the grocery supermarkets
At Toyota, when a process refers to a preceding process to retrieve parts, it uses a Kanban to communicate which parts have been used.
Principles of Kanban Introduction
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Supermarket as a Production Buffer
Make to StockShip to Customer
Production Kanban
Supplier Production Kanban
Principles of Kanban Introduction
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Production Kanban
Part Number Part Description
Location in the Warehouse
Raw Materials requiredQuantity to produce
Production LineRouting: sequence of operations
Principles of Kanban Introduction
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Production e-Kanban
Production Line
Quantity to produce
Raw Materials required
Packaging instructions
Job durationHow long it should take to produce this order
Principles of Kanban Introduction
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Role of Production Control Department There is a very clear customer/supplier relationship between
processes There are several techniques that can be employed but the major
focus must remain on releasing production instruction in a manner that maintains the customer pace and best possible use of existing resources
The flow of material and information as designed by the shikumi is so vital to Toyota that they actually have a department that controls and monitors performance throughout their facilities
This department is called Production Control. It is one of the most powerful departments within the plant and the Corporation
Principles of Kanban Introduction
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Delivery Kanban
FIAMM Technologies - Kanban Loop - Line to F/Gs StoragePart Number Warehouse Storage Location
YF1T-13A803-AC B5Part Description Container Type
YF1T-13A803-AC Ford AM80S Full Size Black ReturnableProduction Line # of Parts per container
Line 5 390Special Instructions # of Boxes per Skid n/a
KANBAN
1. ProductionKanban(what to produce)
2. DeliveryKanban(what to deliver)
In processKanban (flow)
InternalKanban (delivery)
ExternalKanban (Supplier)
SignalKanban (batch)
Principles of Kanban Introduction
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Delivery Kanban – Purpose A visual signal to the Supplier (internal or external) to deliver
materials consumed by a manufacturing process The only authority to move or deliver material - No Kanban; no
delivery Represents a standard pack of parts. It also serves as a container identification We control our inventory levels through the use of Kanban inside
the warehouse or the factory We can easily tell what parts we have and what parts we need –
we do not waste time looking for parts The most common way is with a Kanban Card – but there are
many other ways to signal a need for material delivery
Point-of-Use Location
Point-of-Use Buffers
Library of Kanban Cards
Kanban Post
Re-ordering System
Delivery of Small Boxes
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Format of a Delivery Kanban Card
PartDescription
Warehouse Location Delivery Location
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Types of Kanban - Signal
Card Container
LightEmpty space Electronic
Ball
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Purchased Parts Kanban – cards and containers
These are Material Delivery Kanbans These cards and containers are used to control flow of parts from
the Warehouse to manufacturing Mini Markets or Point-of-Use locations
These Kanbans will be collected several times per day in order to deliver parts to manufacturing Supermarkets
Principles of Kanban Introduction
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Kanban is a Signal
It could be an empty container
Or it could be a card – “Shopping list”
31Marek Piatkowski - F.S.P. Consulting Inc.
Principles of Kanban Introduction
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Container as a Kanban signal
Principles of Kanban Introduction
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Supplier Kanban card Example of Supplier Delivery Kanban Used only in the Purchase Parts Warehouse to order parts from
outside Suppliers Should not be found outside the Warehouse These cards should only be used by the Warehouse and
Purchasing personnel
Principles of Kanban Introduction
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Operating Rules - Kanbans Every box, every tray, every container must have a Kanban card
attached to it. All parts must be stored in one of the three designated locations:
Supermarkets storage Point-of-use (Mini-Market) storage WIP – Flow racks, work stations
Place for every part and every part in its place Inventory is controlled by the number of Kanban cards in each
loop Need more inventory – add more Kanban cards Reduce inventory – pull out Kanban cards
Principles of Kanban Introduction
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Operating Rules
Kanban Cards All permanent Kanban cards and returnable Kanban containers
must be treated as a valuable commodity and a Company property
Do not throw away any Kanbans cards or containers without an approval from the Material Management group
If any Kanbans are found out of place, please report them to the Materials Management group or your Leader
For low volume products (not stored in a Supermarket) we will issue a temporary one time “Make to Order” Kanban card – these cards can be disposed at the end of the process
Principles of Kanban Introduction
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Delivery Kanban – how does this work?
Purchased Parts Purchased parts will be delivered directly to the Point-of-Use or to
the Mini Market in your area – you no longer need to go to the Warehouse
If parts that you need are not in the Mini Market or at the Point-of-Use notify your Supervisor
Delivery Quantities There will be a standard quantity of parts in every tray and
container, as specified by a Kanban card All Purchased Parts will be in stored and delivered in easy-to-use
containers with small quantities of parts inside.
Principles of Kanban Introduction
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Delivery Kanban – how to order parts? When ordering parts from the Supermarket order only what you
need – one container or one Kanban at a time When you empty the container, return it to a designated location
in the storage rack (Mini Market) – for empty Kanbans Return all used Kanbans to a Kanban collection post Pick up the next container only if you need more parts When you finished the job and you have a partial container put the
container on a shelf in the Mini-Market - this partial container should be used first next time you run this job
Principles of Kanban Introduction
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Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
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