Deliver quality products while not overburdening the development team.
Many Japanese entrepreneurs visited some factories several times in the United States to learn about their inventory control systems.
Taiichi Ohno and his colleagues once visited some vehicle assembly plants and foundries, looking for ideas or a system to avoid overstock. They did not find what they were looking for, but in the afternoons, during their trip, they visited supermarkets, and they were very impressed by the way they refilled the items once the customer removed them from the shelf and paid them; that is, the bill was a signal to the supplier that he had to replace the product(s) that the client had just withdrawn.
Kanban is a system that controls the flow of resources in production processes through cards, which are used to indicate when to supply materials. It is based on the demand and consumption of the customer, and not in the planning of the demand.
When is Kanban used?
– When it is necessary to structure the material control and production management system, due to the high mix of products and the volumes that tend to be smaller.
– When the variables of equipment availability, order and cleaning, quick changes, and minimum product batches have been introduced, and the conditions lend themselves to apply kanban.
Procedure to apply kanban:
- Select the part numbers that will be set in kanban.
- Calculate the number of pieces per kanban.
- Choose the type of signal and the type of standard container.
- Calculate the number of containers and the pitch sequence. (Pitch is the production rate according to the quantity of products per package.)
- Track (WIP TO SWIP). This is calculated by dividing the amount of inventory from within the cell, between the inventory-cell standard.)
What is Kanban implemented for?
- Avoid overproduction.
- It allows to work with low inventories.
- Give customers certainty to receive their products on time.
- Allows manufacturing only what the customer needs.
- It is a visual system that allows you to compare what is being manufactured, with what the client requires.
- Eliminates the complexities of production programming.
- Defective products are not passed to the following processes.
- It is removed from a Kanban when a process removes pieces from the previous process.
- The above processes manufacture parts in the quantities specified by the removed Kanban.
- The Kanban provides them with a production order.
- Nothing is produced or transported without Kanban.
- The Kanban makes the function of a production order attached to the articles.
- The number of Kanbans decreases with time.
Kinds of Kanban:
- Retirement kanban: Specifies the class and quantity of products that a process should withdraw from the previous process.
- Production Kanban: Specifies the kind and quantity of products that a process should produce.