Sreejith Bhattathiri M FM-798

The Pull System
• Material is pulled through the system when needed • Reversal of traditional push system where material is pushed according to a schedule • Forces cooperation • Prevent over and underproduction • While push systems rely on a predetermined schedule, pull systems rely on customer requests

. verbal signal etc.Kanban Production Control System • Japanese word for card • Heart of JIT System • Scheduling system that can immediately and clearly communicate demands of customer to the delivery system • Authorizes production from downstream operations • ‘Pulls’ material through plant • May be a card. flag.

• Used often with fixed-size containers • Add or remove containers to change production rate • Kanban card indicates standard quantity of production • Derived from two-bin inventory system • Kanban maintains discipline of pull production .

• Withdraw only the parts needed at each stage. . • Produce the exact quantity of parts withdrawn. • Avoid complex information and hierarchical control systems on a factory floor.Need of Kanban • Level production (balance the schedule) in order to achieve low variability of the number of parts from one time period to the next. • Do not send defective parts to the succeeding stages. • Do not withdraw parts without a Kanban.

and the part types to be produced.Functions of Kanban • Visibility function The information and material flow are combined together as Kanbans move with their parts (work-in progress). . • Production function The Kanban detached from the succeeding stage fulfils a production control function which indicates the time. quantity.

controlling the number of Kanbans is equivalent to controlling the amount of inventory.• Inventory function The number of Kanbans actually measures the amount of inventory. Hence. .

Kanban System “Production” Card “Withdrawal” Card Supplying Process product product Customer Process Finished Goods Store .

A Sample Kanban .

KANBAN SEQUENCE Assembly Area Receiver Post W.O.C. .O. Fabrication Area Supply/Storage Area P.O. P. Production order Post P.

An assembly worker gets a Withdrawal Kanban from the receiver post that tells how many of each item to withdraw from Supply/Storage. Assembly Area Receiver Post W.1.C. Production order Post Fabrication Area Supply/Storage Area .

Assembly Area Receiver Post Production order Post P. The assembly worker goes to the supply point and gets a cart with all the items specified on the withdrawal card. Fabrication Area Supply/Storage Area .2.O. W.C.

Assembly Area Receiver Post Production order Post P. W.O.3. Fabrication Area Supply/Storage Area .C. There is a Production Order card on the cart that the assembly worker removes and places on the receiver post where someone from fabrication will get it.

C.O. Fabrication Area Supply/Storage Area . P.4. Assembly Area Receiver Post Production order Post W. The assembly worker places the withdrawal kanban on the full cart and takes it back to the assembly area to assemble.

Assembly Area Receiver Post P. Fabrication Area Supply/Storage Area . Someone periodically removes the production order kanbans from the receiver post. reviews and sorts them for priority.5. and places them on the production-order post. Production order Post P.O.O.

6.O. A fabrication worker comes to the Production-Order Post and gets a production-order kanban and an empty cart. Fabrication Area Supply/Storage Area . Assembly Area Receiver Post Production order Post P.

. Assembly Area Receiver Post Production order Post Fabrication Area Supply/Storage Area P.O. Fabrication produces the items specified on the Production-Order Kanban delivers them to the supply/storage area.7.

one of which is called `withdrawal Kanban’ (conveyor Kanban) that is carried when going from one stage to the preceding stage. • The primary Kanbans are two kinds. • The other one is called `production Kanban’ and is used to order production of the portion withdrawn by the succeeding stage. .Types of Kanban Primary Kanban: • Travels from one stage to another among main manufacturing cells or production preparation areas.

• Supply Kanban: travels from a warehouse or storage facility to a manufacturing facility • Procurement Kanban: travels from outside of a company to the receiving area. • Subcontract Kanban: travels between subcontracting units. . • Auxiliary Kanban: may take the form of an express Kanban. or a Kanban for a special application. emergency Kanban.

usually less than 10 per cent of daily demand • T= time for a container to complete an entire circuit (lead time) .Calculation of Number of Containers • N = DT/C • Where n = total number of containers • D = Demand rate of the using work centre • C = container size in number of parts.

.Kanban Use • The Kanban system works well in repetitive production environments (Line flows/product focused) • If you are able to achieve small lot sizes and short set-up times. and… • If your suppliers are close by and can make frequent deliveries using a just-in-time system.

Benefits • Reduce inventory level • Less confusion over sequence of activities • Less obsolescence of inventories while in storage • Smaller floor space requirements for storing inventory • Reduce lead time • Improved quality • Higher employee productivity • Greater system flexibility .

Sign up to vote on this title
UsefulNot useful