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Document Sample
Facilities Design
Engr 5301
Topic:
Kanban-An integrated JIT
system.
Presented by:
Anupkumar Nandakumar
On
9th July 2002
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Introduction
• A continuous flow of production or adaptation to
demand, changes in quantities and variety is created
by achieving two key concepts
1. J I T – Just In Time concept.
2. Autonomation.
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JUST IN TIME Manufacturing &
Autonomation
• The idea behind the Just In Time manufacturing
concept is to produce
• Necessary Units in the
• Necessary Quantity at the
• Necessary Time
• Autonomation is concerned with the quality aspect in
which the defective units from a preceding process is
never allowed to flow in to the subsequent process.
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PUSH SYSTEM
• The traditional way of production control
• Push the parts through the subsequent processes
• The central planning approach which determines
and disseminates the production schedules to all
processes simultaneously(Prerequisite for JIT)
• Difficult to implement the JIT in all processes
•Adapting to changes of demands or trouble at some process is
difficult because of scheduling .This causes the holding of inventory
creates an imbalance of stock between processes which leads to
dead stocks,excessive equipment and surplus workers when model
changes take place
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PULL SYSTEM
• The Toyota production system
• The people from the final assembly line goes to the
preceding process to withdraw the necessary units in the
necessary quantities at the necessary time.This is because
only he needs the necessary timing and parts needed.The
preceding process produces only enough units to replace
those that have been withdrawn.this follows down the line
• The prerequisite for the JIT is met by means of the kanban
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What is KANBAN?
• Japanese terms ‘Kan’and‘ban’ refers to ‘card' and‘signal’
respectively
• Tool to achieve JIT production
• Card which is put in a rectangular vinyl envelope
• Informs all processes about necessary timing and quantities
of parts production which is a prerequisite of the JIT
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Types of Kanban
Two kinds of Kanbans are mainly used:
1. Withdrawal Kanban
• Specifies the kind and quantity of product which the subsequent process should
withdraw from the preceding process
2. Production-ordering Kanban
• Specifies the kind and quantity of product the preceding process must produce
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Withdrawal kanban Production-ordering kanban
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Actual Withdrawal Kanban
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Types of kanbans(contd)
• Other kinds include:
•Supplier Kanban
– For making withdrawals from a vendor(subcontractor)
– Therefore a kind of withdrawal Kanban
•Signal Kanban
– Specify lot production .The kanban is tagged to a box in the lot.If withdrawals
are made down to the tagged position of this Kanban production order must
be set in motion
– Two types
• Triangular Kanban
• Material Requisition Kanban
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Supplier Kanban
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Actual Supplier Kanban
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Signal Kanbans
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Types of Kanban(contd)
Framework of the main types of Kanbans
Production kanban
Production-ordering (ordinary)
kanban (For the production other than lot production)
Signal kanban
(For lot production)
Kanban
Interprocess withdrawal
kanban
Withdrawal kanban
Supplier kanban
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How to use various Kanbans
• Starting from the subsequent process
1. Carrier goes to the store of preceding process with the
withdrawal kanbans kept in his post in regular predetermined
intervals
2. He then withdraws parts and detaches the production ordering
kanbans which are attached to each of the pallets and places
that in the kanban receiving post
3. He attaches the withdrawal kanbans in the place of the
production ordering kanban that he detached and placed in the
receiving post
4. When the work begins in the subsequent process the
withdrawal kanbans are put in the withdrawal kanban post
5. In the preceding process,when a certain number of parts have
been produced the production ordering kanbans are collected
and posted in the ordering post in the same sequence as
detached
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How to use various Kanbans(contd)
6.Produce the parts according to the ordinal sequence of the
production ordering kanbans in the post
7.The physical units and the Kanban must move as a pair
when processed
8.The parts produced along with the Kanbans go to the store
so that the subsequent process can withdraw them at any time
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Steps involved in using the kanbans
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Chain of Kanbans and physical units(schematic)
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Kanban rules
In order to realize the JIT purpose of Kanbans following rules
should be followed:
• The subsequent process should withdraw necessary products from the
preceding process in the necessary quantities at the necessary point of
time
• The preceding process should produce its products in the quantities
withdrawn by the subsequent process
• Defective products should never be convened to the subsequent
process(standardization of jobs)
• The number of Kanbans should be minimized
• Kanban should be used to adapt to small fluctuations in demand
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Advantages
• Elimination of unnecessary inventory of work-in-process
• Grasping the overall capacity of production lines and disclosing
the bottleneck process
• Shortening of lead time
• Minimization of the final product inventory
• Prompt adaptability to changes in demands
• Reduction of the storage cost,excessive workforce and thereby
increasing the overall profit
• Improvement in the quality of products
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Limitation
• Limitation of this system is the relative
location of the supplier with the manufacturer
together with the hazardous weather
conditions and traffic conditions
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Strategies by Toyota
• Strategies to deal with the above limitation by
the Toyota company
– Alternative driving routes
– Three step process for assessing and dealing with
delays and emergencies
• Delay less than 2 hours sorted out with transportation
company
• Delay2-3 hrs the plant itself takes action and plays the
central role
• Delay above 3 hrs the inventory in the ‘station’ of the plant
is used
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