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Chapter 9

Chapter 9. Inventory Kanbans Automating the Replenishment Cycle. Kanban. A Japanese word that means signboard or signal. Are signals developed to automate the inventory replenishment cycle for items used repetitively in a facility

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Chapter 9

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  1. Chapter 9 Inventory Kanbans Automating the Replenishment Cycle

  2. Kanban • A Japanese word that means signboard or signal. • Are signals developed to automate the inventory replenishment cycle for items used repetitively in a facility • Communicate the need for additional material to be pulled from the supplier • Integral in a “pull” manufacturing system. IT-465 Lean Manufacturing

  3. Typical Kanban Signal • An empty container designed to hold a standard quantity of material or parts. • The container is sent back to the supplier from the customer when empty. • If returnable containers are not used, a kanban can be as simple as a laminated card. IT-465 Lean Manufacturing

  4. Kanbans • Are: • Communication devices from the point of use to the previous operation. • Purchase orders for your suppliers. • Work orders for your manufacturing area. • Visual communication tools. • Paperwork eliminators. IT-465 Lean Manufacturing

  5. Kanbans • Are not appropriate for: • Single piece or lot production • Safety stock • Systems which push inventory carrying requirements and the associated carrying costs back to the supplier. • Long range planning tools. IT-465 Lean Manufacturing

  6. Kanbans Reduce Waste • Eliminate • Over-production • The need for a stockroom • The need to reissue purchase orders • Reduce: • The data management task for prod plng, work orders • Inventory • Parts expediting • Parts shortages • Material handling IT-465 Lean Manufacturing

  7. Types of Kanbans (Pull Signals) • Cards attached to portable containers such as tote pans • Supplier replaceable cards on cardboard boxes designed to hold a standard quantity • A painted spot or border on the floor around the standardized container • Color coded striped golf balls • E-mails • Bar code labels • Variations of above IT-465 Lean Manufacturing

  8. Summary • Kanbans tie related processes together as if they were connected by an invisible conveyor. Kanbans: • Improve communication • Improve customer satisfaction • Reduce inventories • Reduce waste IT-465 Lean Manufacturing

  9. Pull Systems Outcomes • Define Pull system • Define supermarket • Define kanban IT-465 Lean Manufacturing

  10. Production Scheduling • Constantly change • Production never produces to a schedule • Utilize MRP (Material Resource Planning) IT-465 Lean Manufacturing

  11. Supermarket Pull IT-465 Lean Manufacturing

  12. Scheduling IT-465 Lean Manufacturing

  13. Small-Lot Production + Leveling IT-465 Lean Manufacturing

  14. Leveling Work Volume IT-465 Lean Manufacturing

  15. Leveling Work Volume IT-465 Lean Manufacturing

  16. Flow IT-465 Lean Manufacturing

  17. The Problem with Inventory IT-465 Lean Manufacturing

  18. Kanban Types Production Kanban • “One-per-customer” kanban • Supplying process can produce as little as one container Signal (Triangle) kanban • “One-per-batch” kanban • Signals when a reorder point is reached and another batch needs to be produced • Used in supplying process where changeovers are required Withdrawal kanban • “Shopping list” kanban • Instructs the material handler to get and transfer parts IT-465 Lean Manufacturing

  19. The Six Steps of Kanban • Consumption process withdraws only what is needed • Produce to replenish only what is withdrawn by the next process • Do not send defective products to the next process • Parts must not produced and conveyed when there is no kanban • Kanban must be attached to the actual parts or container • The actual number of parts in the container must match the number on the kanban IT-465 Lean Manufacturing

  20. One Piece Flow Goal • Represents a special case of kanban • Lot size/quantity is one Benefits • Minimizes waste in the process • Defects affect only one component thus creating highest possible quality • Minimizes inventory and space requirements • Keeps pace with customer demand • Efficiently utilizes labor in a balanced process • Best possible throughput in a balanced process IT-465 Lean Manufacturing

  21. Signal Kanban System IT-465 Lean Manufacturing

  22. Summary • Pull Systems • Single scheduling point • Produce to replenish use • Customer demand creates production • Level loading • Kanban IT-465 Lean Manufacturing

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