PRODUCTIVITY AND QUALITY

MANAGEMENT

…………..K-A-N-B-A-N……….

GROUP---1 T.Y.B.B.A-”B”
 PULL …JUST-IN-TIME…
PULLSYSTEM
LEAN MANUFACtURING
SYSTEM

A highly coordinated processing system in

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Material
• Can services
goods
be defined pulledmove
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throughthe
through
integrated
thesystem
set
system, and
of when
activities
are performed, just as
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designed
An inventory strategy that strives to improve a
• using
Reversal
minimalof traditional
business's push system
inventories(raw
return on investment where
materials,
by reducing
material
WIP is pushed
& finished
in-process according
goods)
inventory to a schedule.
and associated carrying
LEAN
•• Involves
costs.
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JUST-IN-TIME
the elimination of waste in
MANUFACTURIN
To meet JIT objectives, the processGrelies on
• production
Prevents over effort
& under production
signals or Kanban
•• Also involves
Relies
Thus,onKanban the timing
customer of production
requests
isKANBAN
directly associated with JIT
resources.
KANBAN-CONCEPT
Card or other device that communicates
demand for work or materials from the
preceding station
Kanban is the Japanese word meaning
“signal” or “visual card.”
Maintain discipline of pull production
Authorize production and movement of
goods
Facilitates what is need, where it is need,
when it is needed.
 …KANBAN SIGNALS…
 When the producer and user are not in visual
contact, a card can be used
 When the producer and user are in visual contact, a
light or flag or empty spot on the floor may be
adequate
 Usually each card controls a specific quantity or
parts
 Multiple card systems may be used if there are
several components or different lot sizes
 Several different kanban techniques may be
employed (markers, empty containers, trolleys, bins,
etc.)
 …KANBAN SIGNALS…

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
…KANBAN BASIC OPERATING SYSTEM…

SUPPLIER FACTORY FACTORY

STORE FLOOR
 …FORMS OF KANBAN…
Production kanban
◦ authorizes production of goods

Withdrawal kanban
◦ authorizes movement of goods

Kanban square
◦ a marked area designated to hold items

Supplier kanban
◦ rotates between the factory and suppliers
 …KANBAN PROCESS…

Kanban Finished Customer

goods order
Work
cell
Ship

Raw Final Kanban

Material assembly
Supplier
Kanban Kanban
Sub-
Purchased assembly
Parts Kanban
Supplier
 …E-KANBAN…
E-Kanban systems can be integrated into
ERP systems.
Facilitates real-time demand signaling
across the supply chain and improved
visibility.
Help to eliminate common problems such
as manual entry errors and lost cards.
Better tracking of supplier lead and
replenishment times.
 …Kanban Replishment system…
Kanban’s represent replenishment signals that are usually manual and
highly visible.

An empty bin that is moved to the supply location to trigger

replenishment.

The system provides support for external devices.

Kanbans can be sourced from an external supplier or an internal

organization

Kanbans are generally replenishable and cycle through the system from
full to empty.
 ….NO- CARD…
With this No Kanban Card Feature, kanban cards are eliminated and
replaced with a wireless Kanban Replenishment System.

Integrated system is designed to eliminate all the non-valued added

movement and handling of physical kanban cards with a wireless Kanban
Replenishment System.

This system knows how each kanban is replenished and by what type of
vendor.

This function accelerates the kanban replenishment system without the

additional burden and delay of physical kanban card circulation
…Kanban inventory systems…
This system analyzes the actual usage of our client's products to
determine the specific type of shipment needed.

We do this by determining the economic order quantity (EOQ).

Your KanBan size is based on your estimated annual usage of the

part and the packaging requirements.

With this information we create a system of inventory

management that includes stocking an extra shipment of parts.

This saves shipping time and costs, keeps the customer's production line moving,
and ensures that the customer will always get their parts when they need them.
…TYPES OF KANBAN…
 …One card system…

A signal is sent back from the consuming

process to supplying process (or supplier).
This is a signal:
To send some more (a transfer batch), via a
buffer stock.
To produce some more (a process batch), at
the supplying work centre.
 …Input output control kanban…
Sometimes called the ConWip (constant work
in process) system, this signal travels directly
from the end of a line or section to the
preceding section or raw material stores.
In this case the supply chain is treated as one
unit rather than a series of linked operations.
So, as one transfer batch is completed
(output) another is launched on the first
operation (input), thus ensuring that work in
process cannot build up.
 …Kanban accumulator…
In this method Kanban signals are
allowed to accumulate at the supplying
work centre until the production batch
size is reached.
In this case buffers can be depleted or
exhausted depending on the
accumulation rules. Also because
buffers can be exhausted, slightly higher
mixes can be accommodated.
 …Dual card systems…
 There are in fact now two types of two card system.
 The first method separates the replenishment (send
some) signal, which is produced from the Kanban
system, from the "produce" signal, which is produced
by a scheduling system such as MRP. The purpose of
each of the cards is as follows:
1. The scheduling system says which job is next.
2. The Kanban says make it now. (I need some.)
 The second variant of this method generates the
second card (after authorisation) as a result of one or
more replenishment requests in a similar way to
Kanban accumulators above
 …Variable Quantity (fixed
frequency) System…
In some situations it is more convenient to
replenish items used, by fixed frequency
deliveries (or collections), rather than
respond to fixed quantity replenishment
requests.
This method forms the basis of supplier "top
up at point of use" systems, where a supplier
visiting your point of use will top up stocks to
a predefined maximum level.
...VIDEOGRAPHIC PRESENTATION…
 …Functions of Kanban…
Production Management Tool.
Visual Control Tool.
Kaizen Tool.
 …Benefits of Kanban…
Reduce Inventory
Improve work flow
Prevent Overproduction. 
Improves responsiveness to changes in
demand. 
Reduces waste and scrap.
Provides flexibility in production.
Increases Output.
Reduces Total Cost.
 …Limitations of Kanban…
Surges in mix or demand cause problems.
It is less effective in shared-resource
situations.
Kanban in itself doesn't eliminate
variability.
Kanban systems are not suited for
manufacturing environments with short
production runs, highly variable product
demand, poor quality products, and a
multitude of product types.
 …Limitations of Kanban…

A breakdown in the kanban system can

result in the entire line shutting down.
The throughput of a kanban system is not
managed but is instead a result of
controlled WIP and known cycle times.
 …Supermarket…

•The location where a predetermined standard

inventory is kept to supply downstream processes.
•Each item in a supermarket has a specific location
from which a material handler withdraws products in
the precise amounts needed by a downstream
process
•As an item is removed, a signal to make more (such
as a kanban card or an empty bin) is taken by the
material handler to the supplying process
 … Cont.

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 regional
warehouse detailing which items have
sold. The warehouse prepares a (usually)
daily replenishment of the exact items
sold.
 …Modern Supermarkets…
Signals come from checkout scanners.
They travel electronically (usually once
a day) to the warehouse.
 Smaller stores still use visual systems.
Here, a clerk walks the aisles daily.
From empty spaces he deduces what
sold and orders replacements
 …Tesco…
In the Tesco system, we have seen
example of a kanban driven production
system, dedicated to a single product.
Here is a more elaborated Tesco holding
three different references, each having
its kanban.
Production operator receives "orders"
through kanban cards returned after
consummer picked his goods.
Kanbans are placed to be visible, on a
scheduling panel per product type. The
operator understands visualy
that MAUVE products are less numerous in
stock, consistently with the rule: one
kanban = one product.
The operator will changeover production to
manufacture two MAUVE units, and if nothing
changes, change again for one ORANGE unit,
whichdont kanban is.. BLUE.
 …Cont.
GREEN If kanban cards are all in green zones,
operator chooses next production.
ORANGE If one product reference has its kanban
cards overflowing into orange zone, he'll change his
production for this reference. Proper adjustment of
zones (stocks levels) allows normal delivery.
RED If one product reference has its kanban cards
overflowing into red zone, this means absolute
emergency. Operator has to change immediately to
this reference and expedite as soon as a minimum
quantity is available.
 …Vending machines…

Vending machines are a pretty

good example of supermarket system.
The slots (number of rows in front and
places in depth) are set accordingly to
sales (consumption).
Fast movers (most sold products) will
get more slots than slow movers
(least sold products
 
ARIGATOU GOZAIMASU ( Japanese thank you)

AKSHAY KOTHARI-167
RAHUL DEORAH-164
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