Simple Steps to Implement Kanban in Lean Manufacturing

®ACTSol & Associates (Avinash Consulting & Turnkey Solutions & Associates)
Website: www.actsol.in, E – Mail: connect@actsol.in Cell No: +91 94835 11055
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LEAN HOW TO IMPLEMENT KANBAN IN LEAN MANUFACTURING Overview

WASTE IN OPERATIONS – WASTOLOGY

THE BASIC ELEMENTS OF LEAN PRODUCTION SYSTEM

Flexible Resources
Cellular Layouts
Pull Production System
Kanban Production Control
Small Lot Production
Quick Setups
Uniform Production Levels
Total Productive Maintenance
Supplier Networks

WHAT ARE KANBANS?

A Kanban is a Visual Information System established to maintain the
DISCIPLINE of a JIT System on the shop floor.
Kanban (Japanese) : Card or Visual Record.
In The Modern Lean Terminology……..,
A SIGNAL THAT AUTHORIZES PRODUCTION

HOW DOES A KANBAN SYSTEM WORK?
& TYPES OF KANBANS

Single Card Kanban
In a Single Card Kanban System, the operator of a down stream operations requires a
Production Card and the necessary Material to be authorized to begin processing.
He/she simply removes the Card and sends it back to the upstream process, signaling
production to replenish the material used by his/her station prior to processing the
job.

When stock is removed place
production card in hold box.
Production card authorizes
start of work.
Full Container
Production Box
Workstation
Kanban card Container being filled
Container being emptied
When stock is removed place
production card in hold box.
Production card authorizes
start of work.
Outbound
Stock Point
Outbound
Stock Point
Outbound
Stock Point

Two Card Kanban System
A Two Card Kanban is used when WIP cannot be effectively handed from one process
to the next, thus necessitating an Inbound Stock Point and an Outbound Stock Point for
processing stations. Mainly this system is utilized in heavy transaction, high complexity
parts (huge number of parts)
In this System Two Cards are used :
• Move (Conveyance) Card : To Authorize the Movement of material
• Production Card : To Authorize the Production.

Part number : 33311-3501
Container capacity : 50
No. of kanban released : 7 of 12
Downstream work center: K123
Stock location no.: A-12
Stock location no.: A-07
Upstream work center: Y321
Two Card Kanban System – Move Card

PROCESS 1 PROCESS 2
1
New stock
moved into
Process 2
Move
kanban
detached
2
Move kanban
attached to
new stock
3
Production
kanbans
direct the
production
sequence
B
Production
kanban
attached
to finished
quantity
C
OUTBOUND
STOCK AREA
INBOUND
STOCK AREA
MOVE KANBAN (1-2-3)
Each process has an inbound and an outbound stock area. The inbound area contains raw materials used in the process. The outbound
area holds completed output from the process.
When Process 2 begins to consume the contents of a container, the Move Kanban is taken off the container and brought to the outbound
stock area of Process 1. There the Move Kanban is attached to a new, full container, which is taken back to the inbound stock area of
Process 2, ready for use.
Dispatch
Box
Production kanban
detached, placed
in dispatch box
A

Work Center no.: Y321
Part number to be produced: 33311-3501
Container capacity: 50 units
Stock capacity at which to store: A-07
Materials Required:
Material no. 33311-3504
Stock location: A-05
Part no. 33825-2474
Stock location: B-03
Two Card Kanban System – The Production Card

PROCESS 1 PROCESS 2
1
New stock
moved into
Process 2
Move
kanban
detached
2
Move kanban
attached to
new stock
3
Production kanban
detached, placed
in dispatch box
A
Production
kanbans
direct the
production
sequence
B
Production
kanban
attached
to finished
quantity
C
OUTBOUND
STOCK AREA
INBOUND
STOCK AREADispatch
Box
PRODUCTION KANBAN (A-B-C)
A Production Kanban is attached to every container in the outbound stock area at Process 1. When Process 2 comes to remove a container
of parts, the Production Kanban is taken off and put in a dispatch box for Process 1.
Process 1 may make parts for several other processes, therefore, it builds the new parts in the order in which the kanban are placed in the
dispatch box. When a container is full, the Production Kanban is attached to it and it is placed in the outbound stock area ready for
withdrawal by Process 2.

SOME SAMPLE KANBAN CARDS

COMMONLY USED KANBAN SYSTEMS – Some Schematic Layouts

THE KANBAN SUPPLY CHAIN

SOME KANBAN FLOW DIAGRAMS

CUSTOMER
REQUEST
KANBAN TICKET
ORDER STOCK
FROM SUPPLIER
DESPATCH ORDER
TO CUSTOMER

MISCONCEPTIONS OF KANBAN

It is seen as a pure production method having little or nothing to do with the
surrounding environment
Kanban focuses on the mathematical complexities of Kanban or elaborate abstract
rules of operating Kanban with inadequate attention to its practicality and
implacability on the shop floor.
We need to keep the above misconceptions to rest by developing an easy to
implement set of operating rules in the plant.

HOW TO IMPLEMENT KANBAN

Three Phases
Phase Particulars
Induction
Implementation
Evaluation
Model Area Selection, Training, Design of
Kanban and Board
5S, SMED, Multi Skilling, SPC and Operating
Rules.
Pilot Run, Evaluation against Set Values of
Parameters

MASTER SCHEME
Month 1 Month 2 Month 3 Month 4 Month 5
1 2 3 4 1 2 3 4 1 2 3 1 2 3 1 2 3
Selection of model
area
Layout
improvement
Multifunction
workmen training
Reduction of setup
time by SMED
Pilot run

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• Email: connect@actsol.in
• Contact No: +919483511055
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Simple Steps to Implement Kanban in Lean Manufacturing

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Simple Steps to Implement Kanban in Lean Manufacturing