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    Kanban System

    Uploaded by

    Aswin Sankar
    Kanban is a lean production system that was developed by Toyota to improve manufacturing efficiency and reduce waste. It uses visual signals to trigger the production or movement of goods. Kanbans have two main types - withdrawal kanbans signal when parts are ready to move between production steps, while production kanbans provide all the details needed for production of a part including materials and quantities. The Kanban system provides benefits like reduced inventory and obsolescence, less waste and scrap, production flexibility, increased output, and lower total costs.

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    Kanban System

    Uploaded by

    Aswin Sankar
    547 views17 pages
    Kanban is a lean production system that was developed by Toyota to improve manufacturing efficiency and reduce waste. It uses visual signals to trigger the production or movement of goods. Kanbans have two main types - withdrawal kanbans signal when parts are ready to move between production steps, while production kanbans provide all the details needed for production of a part including materials and quantities. The Kanban system provides benefits like reduced inventory and obsolescence, less waste and scrap, production flexibility, increased output, and lower total costs.

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    Overview of kanban

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    Kanban is a lean production system that was developed by Toyota to improve manufacturing efficiency and reduce waste. It uses visual signals to trigger the production or movement of goods. Kanbans have two main types - withdrawal kanbans signal when parts are ready to move between production steps, while production kanbans provide all the details needed for production of a part including materials and quantities. The Kanban system provides benefits like reduced inventory and obsolescence, less waste and scrap, production flexibility, increased output, and lower total costs.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    547 views17 pages

    Kanban System

    Uploaded by

    Aswin Sankar
    Kanban is a lean production system that was developed by Toyota to improve manufacturing efficiency and reduce waste. It uses visual signals to trigger the production or movement of goods. Kanbans have two main types - withdrawal kanbans signal when parts are ready to move between production steps, while production kanbans provide all the details needed for production of a part including materials and quantities. The Kanban system provides benefits like reduced inventory and obsolescence, less waste and scrap, production flexibility, increased output, and lower total costs.

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    KANBAN SYSTEM

    Presented by
    Aswin Sankar

    Introduction
    Kanban

    was developed by Taiichi Ohno, an industrial


    engineer at Toyota, as a system to improve and
    maintain a high level of production

    It was implemented in the year 1953 at Toyota


    Kanban is a scheduling system for lean and just-in-time
    (JIT) production

    Kanban is a system to control the logistical chain from a

    production point of view, and is an inventory control


    system

    Kanban is one method to achieve JIT

    The word Kan means "visual and the word "ban" means

    "card". Roughly interpreted.. Kanban refers to "visual


    cards".

    What

    is a visual card? It is a visual aid that triggers


    action.

    A system of continuous supply of components, parts and

    supplies, such that workers have what they need, where


    they need it, when they need it.

    A visual signal to either move or make something.


    Supports PULL, pulling the product at the demand of the
    customer (VS PUSH)

    Kanban
    1. User
    removes
    a
    standard
    sized
    container
    2. Signal is seen by the
    producing department
    as authorization to
    replenish

    Signal
    marker on
    boxes
    Part numbers
    mark
    location

    Everyday Example
    A signal to replenish..

    Types of Kanbans

    The two most common types of Kanbans used today


    are:

    1. Withdrawal (Conveyance) Kanban


    2. Production Kanban

    Withdrawal (Conveyance)
    Kanban

    Withdrawal

    kanbans, also called conveyance kanbans


    or "move cards" are used to signal when a part is ready
    to move from one part of the production process to
    another.

    The

    card is attached to a prescribed number of parts,


    which are moved to the work area that requires them.
    Once the parts are used, the card is returned as a
    signal to send the same number of the same part back.

    Production Kanban

    A production kanban contains a comprehensive list of


    everything the part requires in order to be completed.

    This

    includes the
    required and the
    withdrawal kanban.

    Essentially,

    materials required, the parts


    information included upon a

    a production kanban orders the


    production system to get started with production, as
    well as explaining what must be produced

    Six Rules for an Effective Kanban


    System
    To ensure a proper setup of Kanban in the workplace,
    Toyota has provided us with six rules for an effective
    Kanban system:

    1)Never pass on defective products


    2)Take only what is needed
    3)Produce the exact quantity required
    4)Level the production
    5)Fine-tune production
    6)Stabilize and rationalize the process.

    BENEFITS

    Reduce Inventory and Product


    Obsolescence

    Since component parts are not delivered until just before

    they are needed, there is a reduced need for storage


    space. Should a product or component design be
    upgraded, that upgrade can be included in the final
    product ASAP. There is no inventory of products or
    components that become obsolete.

    This

    fits well with the Kaizen system on continual


    improvement. Product designs can be upgraded in small
    increments on a continual basis, and those upgrades are
    immediately incorporated into the product with no waste
    from obsolete components or parts

    Reduces waste and scrap

    With

    Kanban, products and components are only


    manufactured when they are needed. This eliminates
    overproduction.

    Raw

    materials are not delivered until they are


    needed, reducing waste and cutting storage costs.

    Provides flexibility in production

    If

    there is a sudden drop in demand for a product,


    Kanban ensures you are not stuck with excess
    inventory.

    This

    gives you the flexibility to rapidly respond to a


    changing demand.

    Increases Output

    Kanban reduces wait times by making supplies more


    accessible
    barriers.

    This

    and

    breaking

    down

    administrative

    results in an increase in production using the


    same resources

    Reduces Total Cost


    The Kanban system reduces your total costs by:

    Preventing Over Production


    Developing Flexible Work Stations
    Reducing Waste and Scrap
    Minimizing Wait Times and Logistics Costs
    Reducing Stock Levels and Overhead Costs
    Saving Resources by Streamlining Production
    Reducing Inventory Costs

    Video

    Thank You

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