| Getting Started With kanban
Introducing Kanban Into Your Facility
Kanban is usually introduced gradually and typically may involve some trail and error.
1. The first step is to become
familiar with Kanban and the options it offers. Some parts of Kanban may be suitable for your company, others may not.
2. Select the components of Kanban that will work in your
facility. Not all parts of Kanban may be appropriate for the type of products you produce. Kanban may be appropriate for one product , and not for another. In some case a simple manual kanban will work well. In other cases computer automation of Kanbans may be the best option.
You will need to evaluate both your in-house production and your suppliers in order to determine which Kanban options will benefit your facility.
3. Plan your Kanban system Kanban involves more than just
manufacturing. Other functions such as purchasing,
warehousing, shipping/receiving, quality control, transportation, accounts payable and engineering will be involved. Include all of those who will be effected in your Kanban planning and design process.
In planning, keep in kind that your object to have what is needed (supplies, parts, manpower, information, energy, equipment etc.) where it is needed when it is needed.
4. Set goals for Kanban Based on your plan, set a schedule with measurable goals.. What do you want Kanban to accomplish and when should that goal be reached? Determine what will be measured and how it will be measured. Be sure to get baseline measurement of your current manufacturing system and inventory levels, before Kanban is implemented.
5. Begin
implementation of Kanban A common approach to implementing Kanban is to start with a generous number of kanbans -containers,pallets,boxes etc. Then systematically reduce the number of containers until the point at which the supply of materials is just in balance with the rate of use is reached. As containers are removed from the process, it will eventually reach the point at which production is delayed because the next container has not yet arrived. At this point add one container to the system to bring it back into balance.
In using this trial and error approach, be sure a safety stock is available so that production is not interrupted. You identify the point at which there is one too few containers as the point at which material from the safety stock is used.
This trial and error approach should be spread over a significant period of time to allow for normal fluctuations in production. In other words, don't remove a container every thirty minutes. Instead , remove a container once a day, or even once a week.
Benefits of Kanban :
1. Reduce inventory and product obsolescence
Since components parts are not delivered until just before they are needed, there is a reduced need for storage space. Should a product or component design be upgraded, that upgrade can be included in the final product
ASAP. There is no inventory of products or components that become obsolete.
This fits well with the Kaizen system on continual improvement. Product designs can be upgraded in small increments on a continual basis and those upgrades are immediately incorporated into the product with no waste from obsolete components or parts.
Reduce waste and scrap :
With Kanban products and components are only manufactured when they are
needed. This eliminates overproduction. Raw Materials are not delivered until they are needed, reducing waste and cutting storage costs.
Provides flexibility in production:
If there is a sudden drop in demand for a product, Kanban ensures you are not stuck with excess inventory. This gives you the flexibility to rapidly respond to a changing demand.
Kanban also provides flexibility in how your production lines are
used. Production areas are not locked in by their supply
chain. They can quickly be switched to different products as demand for various products changes.
Increases Output:
The flow of Kanban (cards, bins, pallets, etc.) will stop if there is a production problem. This makes problems visible quickly, allowing them to be corrected ASAP.
Kanban reduces wait times by making supplies more accessible and breaking down administrative
barriers. This results in an increase in production using the same resources
Reduces Total Cost :
Kanban system reduces Total Cost by:
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Preventing Over Production
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Developing Flexible Work Stations
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Reducing Waste and Scrap
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Minimizing Wait Time and Logistic Costs
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