5.18 - KanBan

Kanban (in Japanese - ticket or token) is shorthand to describe pull-type material control systems, (i.e. systems that pull materials through the manufacturing process in the order needed) just in time.

This is a typical Kanban card:-

Quantity:	50
Shaft - Part No:	89372
From:	Turning
To:	Grinding

It tells the operator:-

• How many
• The part description and number
• Where they came from
• Where they go next

The Kanban card is often fixed to a box that will carry the parts - so the box can be regard as a Kanban also.
	When the Kanban arrives empty at a machine it tells the operator to make the number on the Kanban and no more.
	If 8 arrive, it tells the operator to make 400 and no more.

Usually the empty boxes are exchanged for full ones. The box is a re-circulating works order to eliminate paperwork.

Designing the Kanban in this way ensures that:-

• The lead time is kept to a minimum
• Only one journey is made to bring the empties and take the full containers.
• To use simple robust Kanban we need to:-
• Identify the regular runners and make special arrangements for repeaters and strangers.
• Level the schedule to make daily and sell daily
• Reduce the change over times on the machines
• Carefully design the system - simulate it and document it
• Train the people who will run it
• Monitor and improve it. Regularly audit it against the manufacturing strategy.