WHAT IS KANBAN?

Kanban also spelled Kamban ) is a Japanese word that when translated literally meaning "signboard" or "visible record", is a concept related to lean and just-in-time (JIT) production.

Kanban is not an inventory control system. Rather, it is a scheduling system that tells you what to produce, when to produce it, and how much to produce. According to Taiichi Ohno , the man credited with developing Just-in-time, Kanban is one means through which JIT is achieved.

 NEED OF KANBAN

The need to maintain a high rate of improvements led Toyota to devise the Kanban system. Kanban became an effective tool to support the running of the production system as a whole.

In addition, it proved to be an excellent way for promoting improvements because reducing the number of Kanban in circulation highlighted problem areas.

PURPOSE OF KANBAN
Kanban act as communication devices from the point of use to the previous operation and as visual communication tools, Kanban act as purchase orders for your suppliers and work orders for the production departments, Kanban reinforce other manufacturing objectives such as increasing responsibility of the machine operator and allowing for proactive action on quality defects.

TYPES OF KANBAN
Dual-Card Kanban

This Kanban system is more commonly referred to as the Toyota Kanban system as Toyota was the first to employ this system in full-scale use. It is a more useful Kanban

technique in large-scale, high variety manufacturing facilities. In this system, each part has
its own special container designed to hold a precise quantity of that part. Two cards are used: the production Kanban, which serves the supplier workstation, and the conveyance Kanban, which serves the customer workstation.

 Single-Card Kanban

The single-card Kanban system is a more convenient system for manufacturing facilities requiring less variety in their parts. Essentially, the single-card Kanban

system is simply a dual-card Kanban system with the absence of the production
Kanban and designated stock points.

Kanban Scheduling

Kanban scheduling systems operate like Supermarkets. A small stock of every item
sits in a dedicated location with a fixed space allocation. Customers come to the store and visually select items. An electronic signal goes to the supermarket's regional warehouse detailing which items have sold. The warehouse prepares a (usually) daily replenishment of the exact items sold. In modern supermarkets Kanban signals come from checkout scanners. They travel electronically (usually once a day) to the warehouse.

Kanban Scheduling In Manufacturing

A machine shop supplies components to final assembly. Assembly is a manual operation with little setup and produces in lot sizes of one, to customer requirements.

Machining is more automated and has significant setup costs. Machining produces in
batches to amortize the setup and sequence parts to minimize tool changes. A small quantity of each part is maintained at machining. By observing the quantities, the machinists know what products need to be made.

FISHBONE

Dr. Kaoru Ishikawa, a Japanese quality control statistician, invented the fishbone diagram. Therefore, it may be referred to as the Ishikawa diagram. The design of the diagram looks much like the skeleton of a fish. Therefore, it is often referred to as the fishbone diagram. It is also called as cause-and-effect analysis.

What is Fishbone/Cause-and-Effect /Ishikawa Analysis ?

A cause-and-effect analysis generates and sorts hypotheses about possible causes of problems within a process by asking participants to list all of the possible causes and effects for the identified problem Cause-and-effect diagrams can reflect either causes that block the way to the desired state or helpful factors needed to reach the desired state.

When should a fishbone diagram be used?

Need to study a problem/issue to determine the root cause?

Want to study all the possible reasons why a process is beginning to have
difficulties, problems, or breakdowns? Need to identify areas for data collection? Want to study why a process is not performing properly or producing the desired results?

Fishbone Diagram Example 1

This fishbone diagram was drawn by a manufacturing team to try to understand the source of periodic iron

contamination. The team used the six generic headings to

prompt ideas. Layers of branches show thorough thinking about the causes of the problem.

Measurement Materials

Methods

Environment Manpower

Machines

What is Jidoka?
Jidoka is providing machines and operators the ability to detect when an

abnormal condition has occurred and immediately stop work. This enables
operations to build-in quality at each process and to separate men and machines for more efficient work.

Jidoka is one of the two pillars of the Toyota Production System along with just-in-time.

Jidoka is sometimes called autonomation, meaning automation with human intelligence.

Why Jidoka?
Increase quality

Lower costs

Improve customer service

Reduce lead time

Steps in Jidoka
The four steps in Jidoka are: Detect the abnormality.

Stop.
Fix or correct the immediate condition. Investigate the root cause and install a countermeasure.