Kanban Database

Process: Purpose: Reference:

Material control process Low inventory and material on time Kanban91221
30a-ProcessTiming

KANBAN SETUP DATA 30 HOW TO BUILD

1 Updated / Name: <enter name> 1. Define customer-demand and enter de
2 Updated / Date: <enter date> 2. Decide on value of Kanban-card (KVAL
3 Owner / Name: <enter name> - quantity per card determines frequenc
4 Owner / Contact: <enter contact> - quantity of cards determines inventory
5 Factory / Name: <enter factory> 3. Print this table and review data with all
6 Customer / Name:: <enter customer> 4. Print cards, fold and laminate them > tr
7 Comment / Status: <enter comment> 5. Monitor closely until system is stable >

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# NAME FREF SUP SREF DEM ITEM PACK SHIP IPP
1 Coca Cola SAP-1234 WalMart WM-6789 2 Can 0.33l Carton Box 24
2 Butter SAP-0021 Publix PX-54a 0.1 Pack 0.25p Pack Pack 1
3 Screws-HT47/3 SAP-0099 HomeDepot HD-4932 500 Screw1.25 Box Carton 100
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12 INFORMATION
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14 This sheet is for information only.
15 The tool is part of the professional
16 package, available for download on:
17 www.leanmap.com
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 Leanmap.com
Navigating to Results

nce: Responsible: Date:

91221 Enter Name 1/1/2020

HOW TO BUILD A PULL-SYSTEM

-demand and enter demand and supply data in table below
of Kanban-card (KVAL), how many items one card controls
rd determines frequency of replenishment
ds determines inventory (work in process + safety-stock)
nd review data with all departments up and downstream
and laminate them > train people in function & handling.
until system is stable > adjust number as needed

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MOP PPS L/T DPT LOC KVAL KQTY COMMENT/CONDITION
16 16 3 Kitchen F2 16 5 Go shopping twice per week > lead-time is 3 days
1 1 3 Kitchen FridgeC4 0.5 1 Buy new pack when just 0.5 pack is left
10 25 5 MachShop B5 10 3 Dem=5boxes/day, order=10box, inventory=30boxes
45-KanbanCard Leanmap 'Navigating to Results' Process - creating a Kanban-card in 4 steps:
45
Kanban Designer enter index to select part > 1 (1) enter data in database > (2) select index number > (3) print card > (4) fold and laminate card.

Supplier=WalMart Factory=<enter factory> Location 1 Card is Total Supplier=WalMart Factory=<enter factory> Location 1 Card is Total

Coca Cola
SupplierRef=WM-6789 FactoryRef=SAP-1234 Kitchen Carton
F2 3 5
Cards
Coca Cola
SupplierRef=WM-6789 FactoryRef=SAP-1234 Kitchen Carton
F2 3 5
Cards
Creator: <enter name> Item Pack Ship Time Qty Creator: <enter name> Item Pack Ship Time Qty

Can 0.33l

Can 0.33l
Updated: <enter date> Updated: <enter date>

Carton

Carton
Order

Order
Days

Days
Owner: <enter name> Owner: <enter name>

Box

Box
Contact: <enter contact> Contact: <enter contact>
Demand [Units/Day] max expected volume 2.0 0.1 0.0 1.0 1% Demand [Units/Day] max expected volum e 2.0 0.1 0.0 1.0 1%
MOQ [Units/Order] Min-Order-Quantity 384.0 16.0 1.0 192.0 100% MOQ [Units/Order] Min-Order-Quantity 384.0 16.0 1.0 192.0 100%
Buffer Stock to cover 3 days Lead-Time 6.0 0.3 0.0 3.0 2% Buffer Stock to cover 3 days Lead-Time 6.0 0.3 0.0 3.0 2%

Conversion Box Carton Can 0.33l Kanban-Rules Conversion Box Carton Can 0.33l Kanban-Rules
Box 1 6% 0% 1. No material moves without card! Box 1 6% 0%
Carton 16 1 4% 2. See red line > Kanban into box! Carton 16 1 4% 2. See red line > Kanban into box!
Can 0.33l 384 24 1 3. Never loose a card & no copies! Can 0.33l 384 24 1 3. Never loose a card & no copies!

Lead-Time Delivery Lead-Time Delivery

 
Supplier Factory Customer Supplier Factory Customer
-WalMart- -<enter factory>- -<enter customer>- -WalMart- -<enter factory>- -<enter customer>-
MinOrder=16. Carton 3 days Buffer=.25 Carton Demand=.08333 Carton MinOrder=16. Carton 3 days Buffer=.25 Carton Demand=.08333 Carton

licenced by Leanmap® licenced by Leanmap®

Kanban Kanban
(empty) Card (empty) Card

Kanban Kanban
Card Card
Kanban Kanban
red line is visible Box Delivery red line is visible Box Delivery

(full) (full)
Min Order Qty Lead-time Safety-Buffer Demand/day Dem and/day Min Order Qty Lead-tim e Safety-Buffer Demand/day Demand/day
Flow-Data

Flow-Data

16.0 3.0 0.3 0.1 2.0 16.0 3.0 0.3 0.1 2.0
Carton Days Carton Carton Can 0.33l Carton Days Carton Carton Can 0.33l