KANBAN The Pull System

Presented by Shreyasi Ranjan Shrishti Gupta

KANBAN- AN INTRODUCTION
A system of continuous supply of components and parts such that workers have what they need, where they need it and when they need it. KAN VISUAL BAN SIGNAL Kanban is a method for developing products with emphasis on just in time manufacturing process in which movement of material through a process are recorded on specially designed cards. Kanban limits the amount of inventory in the process by acting as an authorization to produce less inventories

KANBAN- AN INTRODUCTION
The kanban schedule uses visual signals and predetermined decision rules that allow the production operators to schedule the line.

The kanban system is so often referred to as the supermarket system because it is based upon the U.S. model in which customers pull goods off the shelf and stock clerks replenish the inventory based on consumption.
Kanban allows employees to acquire from upstream processes, only the goods that are needed, when they are needed, and only in the required amount.

PURPOSE OF KANBAN
The KANBAN is a method for controlling production and the material flow is based on the actual stock quantity in production. Material that is required on a regular basis is continually provided in small quantities in production. With KANBAN, the production process controls itself and manual posting is reduced as far as possible. The effect of this is a reduction in lead time and in stock

THE NUMBER OF KANBAN CARDS OR CONTAINERS

Need to know the lead time needed to produce a container of parts Need to know the amount of safety stock needed

Number of kanban(containers) = Demand during Safety lead time + stock Size of container N= dL+ S , Where, N=No of Kanban C d= Average demand over some period of time L= Lead time to produce parts S= Safety stocks L= Container size

NUMBER OF KANBANS REQUIRED

Average demand (d) =150 shirts Production lead time (L) =0.5 hrs (Wait time + Material handling time + Processing time) Safety stock =5% of dL = 5% of (150*0.5) So, safety stock = 3.75 Container size =24 shirts

Number of kanbans = 75+ 3.75 24

= 3.28 kanbans

KANBAN- THE PULL SYSTEM

Method of controlling and balancing of the flow of resource. Eliminating waste of handling, storage, rework and minimize WIP. Manufacture and ship only what has been consumed. Provides visual control of all resources

KANBAN- THE PULL SYSTEM

TYPES OF KANBAN
Raw material kanban: It tells the supplier when to send how much of a particular item to a particular place. In process kanban: It determines the amount of WIP that can be kept between ant two operations in a process.

Finished goods kanban: It determines the amount of product to be kept on hand at any given time. Removal of finished goods kanban acts as a signal for more of that product to be manufactured.

RULES TO IMPLEMENT KANBAN

Visualize Workflow - A visual representation of the process helps

to see exactly how tasks change from being not done to done right. Creating a kanban board allows you to see the status of the work being done at a glance
Limit Work in Process (WIP) - Whether a project is simple or

complex or whether the team is small or large, there is an optimal amount of work that can be in the process at one time without sacrificing efficiency. based on objective measurements, and kanban is no different.

Measure and Improve Flow - Improvement should always be

STEPS TO IMPLEMENTING KANBAN

Conduct data collection Calculate the kanban size Design the kanban Train everyone Start the kanban Audit and maintain the kanban Improve the kanban

KANBAN- HOW IT WORKS

The work center further down the line (demand source) requests material from the preceding work center (supply source) only when it is required (PULL PRINCIPLE). For this purpose, a control cycle is created - with a fixed number of kanbans (cards) - between the supply source and the demand source
Each kanban represents a specific material quantity and usually represents a container (however, this need not be the case). When the material quantity of a kanban has been consumed, it is given the status EMPTY and is sent to the supply source.

KANBAN- HOW IT WORKS

The kanban is the signal for the supply source to go ahead and produce the quantity of material recorded on the kanban. Once production is complete, the material is delivered to the demand source which confirms the receipt of the material by setting the status back to FULL. The lot size is determined by the kanbans and this quantity is produced by the supply source in one run.

The total production quantity is calculated by the total number of kanbans sent to the supply source within a predefined period

KANBAN- HOW IT WORKS

Replenishment frequency is based on actual consumption. This means that if more material is required, the kanbans simply circulate between the supply source and the demand source more quickly. If less material is required, the kanbans circulate more slowly. If no material is required, then all the kanbans will remain at the demand source with the material, meaning that all of the components required to start producing the corresponding assembly are available.

ADVANTAGES OF THE KANBAN PROCESS

A simple and understandable process Provides quick and precise information Provides quick response to changes Limit of over-capacity in processes Avoids overproduction Minimizing waste Control can be maintained Reduces cost of keeping inventory Tool for visual control Improves workflow

THANK YOU!