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Kanban Training

Kanban Training. A Comprehensive Training Tool for Using Kanban. Agenda. Defining Kanban Brainstorming Exercise Kanban in Depth How it works Example of Kanban Exercise using Kanban Summary. Defining Kanban. Kanban is Japanese for “card, ticket, sign, or signboard.”

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Kanban Training

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  1. Kanban Training A Comprehensive Training Tool for Using Kanban

  2. Agenda • Defining Kanban • Brainstorming Exercise • Kanban in Depth • How it works • Example of Kanban • Exercise using Kanban • Summary

  3. Defining Kanban • Kanban is Japanese for “card, ticket, sign, or signboard.” • Comes from Toyota’s Production System • Manages flow of production and materials • Used in a JIT “pull” system

  4. After Using Kanban Before Using Kanban

  5. Brainstorming Exercise • Goals and hopes for kanban • Why are you implementing this system? • What will a pull system do for you, the company, your employees? • What are some things you could do with the potential savings from using kanban?

  6. Kanban in Depth • Kanban card example • System attributes • Types of kanban cards • Functions • Rules

  7. Kanban Card Special Instructions Part Number Description Order Quan. Card 1 Container Kanban Card Example Supplier Pull From

  8. System Attributes • Material vs. Production cards • What to pull/produce • When to pull/produce • How much to pull/produce • Where to pull from • Visual process helps people

  9. System Attributes • Kanban is used to eliminate waste and level production • Typical production looks like this:

  10. Functions • Serves as the “nervous system” for production • Improve and strengthen the factory

  11. Rules • Don’t send defectives to the subsequent process • The subsequent process comes to withdraw • Produce only the quantity withdrawn • Equalize the processes • Kanban is a means to fine tuning • Stabilize and rationalize the process

  12. How Kanban Works • Push vs Pull activity • Calculating: • How many kanbans are needed • Finding takt time • How many operators are needed • ABC Classification

  13. Signal sent from Customer Material Kanban Production Kanban Kanban System Customer Final assembly Suppliers Production Process

  14. Calculating How Many Kanbans • # of Kanbans • Daily output • Mnfting • Safety margin: zero days or as few as possible • Pallet capacity: keep pallet contents small but receive more deliveries

  15. Finding Takt Time • Takt time is the rate at which products/parts must be produced to fulfill customer orders • T • O

  16. How Many Operators Needed • # of operators needed • Need to find TCT

  17. ABC Classification • A- frequently ordered items, high volume • B- somewhat frequently ordered, medium volume • C- infrequently ordered, small volume

  18. Example of Kanban • US Synthetics has been using lean principles, including kanban • USS was able to stabilize their production, along with their customers’ and suppliers

  19. US Synthetic 7 Years Ago • Batch Processes (Extremely Difficult To See and Fix Problems) • Production Forecast (Almost always wrong) • Push Systems (Producing even if there is no demand) • Hero mentality / Constant Expediting • Working overtime, but never working on the right stuff Supplier Customer

  20. Going Lean, Using Kanban Supplier Customer

  21. US Synthetic Kanban

  22. US Synthetic Customers

  23. Exercise for Kanban • Demand Analysis

  24. Demand Analysis Worksheet

  25. Finished Demand Analysis

  26. Summary • Define Kanban • Brainstorm Exercise • Kanban In Depth • Material vs. Production Kanban • Rules of Kanban • Activity Review

  27. Questions?

  28. Reading List • Kanban, Just-In-Time At Toyota by Japanese Management Association-David Lu • Kanban For The Supply Chain by Stephen Cimorreli • Implementing a Mixed Model Kanban System by James C Vatalaro • Kanban For The Shopfloor by Productivity Press Development Team

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