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Kanban: David Chen IMS, University Bordeaux 1

1) Kanban is a lean manufacturing system that uses visual signals to trigger production only in response to actual customer demand. 2) In a Kanban system, physical cards represent units of production and flow between processes to signal the need for more units to be produced. 3) The number of Kanban cards in circulation between processes is determined based on factors like average demand, lead time, container size, and risk allowances to avoid overproduction.
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0% found this document useful (0 votes)
100 views23 pages

Kanban: David Chen IMS, University Bordeaux 1

1) Kanban is a lean manufacturing system that uses visual signals to trigger production only in response to actual customer demand. 2) In a Kanban system, physical cards represent units of production and flow between processes to signal the need for more units to be produced. 3) The number of Kanban cards in circulation between processes is determined based on factors like average demand, lead time, container size, and risk allowances to avoid overproduction.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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KANBAN

David Chen

IMS, University Bordeaux 1


Introduction

Just In Time
Juste A Temps:

Taiichi Ohno

 Beginning of 50’s at Toyota


 70s in North America
 End of 80s in France
Introduction

• Objective of Kanban method: Avoid


overproduction;
-> Produce too early is as bad as to produce too
late;
-> Kanban is an information system allowing to
manage physical flow at shop floor level;
Kanban method is very simple but the conditions for
its success are important and sometimes difficult to
implement.
Push / Pull system

MRP method
Programme Production

Kanban method Demand


Production

Push flow vs. Pull flow


MRP / KANBAN
MRP – Push flow

MRP

PO MO
Machine Machine Machine
Supplier 1 2 3 Customer

KANBAN – Pull Flow

Orders kanban kanban Demand

Supplier Machine Machine Machine


1 2 3 Customer
PHYSICAL FLOW
- Between 2 machines there is a flow of certain
number of containers
- A container transports a fixed quantity of products

machine o o o o o o
machine
2 3
INFORMATION FLOW
- Between 2 machines there is a flow of certain number of Kanbans
- They are either on the planning or attached to containers
Planning
Kanban

machine machine
2 3
KANBAN Card
An example : Enterprise CPOAC group
BOSCH (Factory at Bonneville, Haute Savoie)

TUBE CULASSE 59827 O 1. 2

PROVENANCE DESTINATION

114 194 400


TOUR WG Pièces ASSEMBLAGE AUTO
CPOAC
Groupe BOSCH

(Source : A. Courtois et al. 1995)


KANBAN

Examples
PLANNING OF KANBAN

- Visualize kanbans waiting for Planning


production Kanban

- Be informed of problems
downstream (no return of kanban)
- Define a priority for release the
production
- Know the stock of WIP : machine machine
2 3
WIP Stock = (A-B)*C
A: Quantity of Kanbans in circulation
B: Quantity of kanbans on the planning
C: Quantity of products per Kanban
RULES OF WORKING

1° The presence of Kanbans


on the planning = Production

2° No Kanban on the
planning = Stop the production
PROCEDURE

Example for illustration :


Planning
Kanban

2
3

1 machine 5 o o o o o o
machine
2 3
4

6
Determine the priority
Suppose that a machine
manufactures 3 types of parts :

- Reference A : 8 kanbans in
circulation
- Reference B : 5 kanbans in
circulation
- Reference C : 3 kanbans in
circulation

The planning of kanbans is the


following:

Question to the operator:


What part should be manufactured first ?
Determine the number of Kanbans
Empirical Method
Determine the number empirically, step by step, by putting a lot of kanbans at
the beginning then diminishing the number little by little until the flow breaks

Method of calculation

D : the average demand of parts per unit of time (the hour, day, month,...)
L : lead time (delay) to produce one container of parts (which is function of the
production cadence of considered machine )
C : the capacity of a container
G : management factors (representing various possible hazards and risks,
<10% of DxL)

The number of kanbans : n = (DxL+ G)/C


Example
D = 500 parts/h; L = 30 min; C = 50 parts ; G = 20 parts
n = (500x0,5+20)/50
= 6 kanbans
Case study

Enterprise REDIX
The products
The products (R1-R6) have all the same structure:

Réducteur Reduction gear

Gear Engrenage Carter Couronne Rim


Casing
Spare parts
Couronne
phase A sale

Engrenage Carter Couronne


raw
raw material raw material
material
Enterprise REDIX
Production Cadence
Cartes KANBAN
Incidents
REDIX System

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