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Kan Ban
Kanban : Pull System
Updated: June 2nd, 2006
2
Basic Principleof
KANBAN
Kanban : Pull System
Updated: June 2nd, 2006
3
Controls production of the right parts, in the quantities, at the right moment, in every stage of production.
Kanban : Pull System
Updated: June 2nd, 2006
4
An instruction for: withdrawing products from the preceding processProducing the quantity that has been withdrawn
Kanban : Pull System
Updated: June 2nd, 2006
5
Two types of Kanban the Production Instruction Kanban (PIK) the Withdrawal Kanban (WK)
Updated: June 2nd, 2006
6 DEFINITION: kanban card = communication toolTARGETS: Indicate the part number / part name and the quantity to be produced per card Information on the card
- name of the supplier and name of the customer. - point of storage (shopstock) and point of use
KANBAN CARD
Kanban : Pull System
Updated: June 2nd, 2006
7
Assemblyline
Withdrawal Kanban loop
a
b
c
b
PIK
Production instruction Kanban loop
B
A
a
b
C
c
B
A
a
b
C
c
A
a
Supermarket / shopstock
b
WKWK WK To internal customer
Batch Building BoxWK
From internal customer
Instruction Kanban (PIK)
Updated: June 2nd, 2006
8
1. Production batch = 1 Kanban (no changeover) The production order for the reference. A 1 Kanban corresponds to 1 box to produce
2. Production batch = n Kanbans (changeover time) Kanban with batch-building box
Instruction Kanban (PIK)
Updated: June 2nd, 2006
9
When different references are manufactured in the same process with changeover time, the production order is a pack of Kanban (a batch).The production order is not given until the batch has been constituted .
A batch of n Kanbans corresponds to n packaging units to produce. Example: The batch of five Production Instruction Kanbans is the production order.
Withdrawal Kanban
Updated: June 2nd, 2006
10
The order for withdrawing the reference. It is used between sequencer and production line processes within a site to instruct the internal supply team to pick up the parts from upstream.
Withdrawal Kanban
Updated: June 2nd, 2006
11
The downstream process at the end of the line
The sequencer at the end of the line
Circulation of this Kanban must follow two principles:
Simultaneous transfer of the parts and the corresponding information (the Kanban is attached to the packaging unit or part)
Frequent transfer (several times per shift – if possible once per hour)
Batch Building Box
Updated: June 2nd, 2006
12
Batch Building Box
Updated: June 2nd, 2006
13
DEFINITION:
Is a box accumulating the kanban cards in order to build the batch The batch size reflect the flexibility of the production line / machine (Faurecia proposes to invest 10% of the production time in tool change)
The batch building box is placed at the end of the lineTARGET:
build a production batch with a fixed size
Updated: June 2nd, 2006
14
DEFINITION:
reflect the flexibility and reliability of the machine / production line. This stock:*is designed to contain all product variants (or at least the most demanded)*is located at the end of the machine / production line.TARGETS:
allow the customer to pick the parts he needs without waiting the parts to be produced
END OF LINE STOCK
WAITING QUEUE
Updated: June 2nd, 2006
15
The practical way of maintaining the withdrawal order of the packaging units.It represents the manufacturing sequence of the production line and uses gravity to feed the cards.
Updated: June 2nd, 2006
16
DEFINITION: WQ helps to accumulate the batches respecting the FIFO The waiting queue is placed at the beginning of the production line
TARGET: give to the production a clear sequence to be respected for the production of the batches
WAITING QUEUE
6 Rules for Effectiveness
Updated: June 2nd, 2006
17
No bad part may reach next process The number of parts in each packaging
unit must be identical to the number of parts noted on the kanban
The downstream process must withdrawal according to the kanban the exact quantity of the right product at the right time
6 Rules for Effectiveness
Updated: June 2nd, 2006
18
The output of the upstream process must match the quantity withdrawn by the downstream process
The number of Kanbans must been reduced. The number of PIK reflects the stock
levels. It is essential to lower the kanban as progress is achieved.
The Kanbans must be used to adapt to fluctuations in demand
ADVANTAGES
Updated: June 2nd, 2006
19
• Respect the customer demand• Produce at the rythm of the customer (Takt Time)• Visualisation of the production management• Regular and controlled production• Improve the reactivity
Kanban : Pull System
Updated: June 2nd, 2006
20
• Video“Palmela Fixed Batch Kanban”• Kanban Pull Systen Model – Simulation• Shopfloor visit: waiting queue, batch building box, kanban
Standardized Work
Production System Effiency
STANDARDIZED WORK
TRAINING
Definition – Standardized Work
A timed description of the best possible succession of basic manual tasks for an operator.
It includes:- transformation and control operations- but also movements - other necessary steps included in the cycle time.
Objective
Achievement of safety, quality, productivity and delivery performance objectives through:• reduce dangerous movements• apply controls and ability to repeat• correct use of machines• identification and elimination of the 7 wastes• training and evaluation of the operators
Key Factors•Allows the repeatability of the sequence of basic tasks during each cycle with low variability of the process.•Work content may differ according to product options• Separate the man and machine• Reduce frequencial operations (reduce variability)• Quick and efficient treatment process of improvement ideas through the operator
Cycle Time and Takt Time
Takt time is a rate that represents, in seconds, the number of parts the customer expect us to deliver
Cycle time is a rate, in seconds, at which the product must be produced in order to offset “waste” in the system and achieve the Takt Time needed to satisfy the customer
Work ContentSum of the basic tasks carried out at each workstation to obtain a complete and good product (amount of work for a part)It is measured by timing the cycle of each operator using a cycle time measurement form. The measurement must be based on 20 consecutive cycle times (everything included). Time necessary for self-inspection has to be included.For each operator, we will show the minimum time, wait time excluded, as well as the maximun and mean time.
FORMS
The standardized work goal is based on 3 forms:• Standardized Work Chart ( #)• Work Combination Table (#)• Standard Operation Sheet (#)
Standardized Work Chart- describes the succession of basic tasks and the position of the operator for each of them. - helps to visualize easily the operator movements and to identify useless movements- determines the number of parts between each workstation.
Standardized Work ChartOperation from: Date:
to:
Takt Time Expected nb parts waiting
61 s
Cycle time
51 s
Expected number of parts waiting
3
FAU-F-PS-5006 /1
Product: panel Process: welding, assembly
Standardized work chart
Machine 4 (Welding)
Station 5 (Inspection)
FP cart12
3
4
5
6
710
8
9
Qualityinspection
Safety
Movement
with part
without part
Productionname:
date:
Methodsname:
date:
Qualityname:
date:
Sketch operator's workstations. Break his/her work down into elementary tasks corresponding to those in the standard w ork combinaison table.
Number the operator's position for each job
Add symbols
Part awaiting operator (e.g. At end of cycle)
Special hasard or safety action
Work Combination Chart- gathers all the basic identified tasks on the Standardized Work Chart and details each specific time.- helps differentiate times walking and waiting from working on the workstation. - allows to evaluate the difference between cycle time and takt time and to verify that operators do not wait for the machine.
Work Combination Chart
/ / / / / /
SYMBOLS: - MANUAL: AUTO: WALK: IDLE:15
PRODUCT REFERENCE NUMBER:
WORKSTATION ANALYZED BY:
TAKT TIME: Quality
Volume:
DATE:
Production Methods
STANDARDIZED WORK COMBINATION TABLE
TIME OPERATION TIME
WALKAUTOMANUOPERATION NAME
N° 45 60
2
3
15TOTAL
35
30
3
2
310Position part for inspection
Pick waiting part
2Position part
1
5
4Functional inspection 3
15
Place part in cart
3 Weld
Welding inspection
2
3
9 Pick welded part
2
7 Pick inspected part 2
Surface inspection
5
6
8
3
50
3
34
25
2
555 10 40302015
FAU-F-PS-5007 /1
CT = 51s
TT = 61s
Record time spent on:- manual operations - automatic operations- walking (1m = 1s)
Break work down into elementary tasks, numbered as in the standard work chart
Represent the times graphically, differentiating among:- manual time ( ______ )- automatic time (-----)- walking (~~~~)- idle time (====)
Standard Operation Sheet- details all the instructions to realize an operation at a workstation describing it by the safest, easiest and most efficient way.- contrary to the standardized work chart and work combination table relative to an operator, this document is linked to a process or a basic operation from the process.
Standard Operation Sheet
Fig 1.
Fig 2.
Fig 3.
Bolster
Name:
= SAFETY = QUALITY = TIP
STANDARD OPERATION FAU-F-PS-241 / ENversion 02
Part Number xxx Part Name
SKILLEDOPERATOR
Non Conforming Product:Approved Signature/DateIssued Signature/Date Checked Signature/Date
Name: Name:
5 Place one white & green clip into cavities 3&4
- Take one white & green LH clip from the dispenser.- Place the green clip into the center clip position and the white into the bottom location on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl
P lace rejects in reject container. Record on P rocess M onitor Sheet. If 3 or more rejects found with same fault call Gap Leader.Function: Function: Function: Name:
Signature/Date
3 Fold waste and place onto to stand.
Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).
4Remove the spiked frame from the underneath bench
Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)
Ensure that the handle is pointing towards you is fully located against the censor
1 Remove parts from tool Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)
2Remove the spiking frame from the upper tool
Remove the waste then place the frame onto the bench
Ensure frame handle is pointing away from you and spikes are pointing upwards.
Page No: 1/1
No. Operation 30 Sec Sketches / Photo's / etc.
Line : EQ Bolster Work-station: Woodstock
Plant: Washington Document No.: xxxxRevision Level: 4
Cavities
Spiking frame
Cavities
234 1
Granulator
Cooling stand
White
GreenWhite
1 2
3
4
5
Safety issue: to be used if a real riskexists for employees !
Important remarks can be written in bold or underlined
Operator who participatedin setting up the Standard Operation
Non-ComformanciesReaction rules have to be adapted to the workstation
Tip : put the stress on special comments
Whole Time needed according to the Standardized Combination Table
big fontenables operator to read from worstation
"Alt+Enter"to go on the next line in the same cell
Self-Quality check
Time:
Standard Operation Sheet
Fig 1.
Fig 2.
Fig 3.
FAU-F-PS-241 / ENversion 02
Function:
5 Place one white & green clip into cavities 3&4
- Take one white & green LH clip from the dispenser.- Place the green clip into the center clip position and the white into the bottom location on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl
Signature/Date
4Remove the spiked frame from the underneath bench
3 Fold waste and place onto to stand.
STANDARD OPERATION
Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).
Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)
2Remove the spiking frame from the upper tool
Sketches / Photo's / etc. = SAFETY = QUALITY = TIP
Remove the waste then place the frame onto the bench
Ensure frame handle is pointing away from you and spikes are pointing upwards.
Signature/Date Signature/Date
xxxx4
1/1
Document No.:
Revision Level:
WoodstockWashington
Work-station:
Plant:
P lace rejects in reject container. Record on P rocess Monitor Sheet. If 3 or more rejects found with same fault call Gap Leader.
Name: Name:
Non Conforming Product:
Function:
Signature/DateIssued Checked
Name:Function:
130 Sec
Remove parts from tool
Operation No.
Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)
Ensure that the handle is pointing towards you is fully located against the censor
SKILLEDOPERATOR
ApprovedName:
xxx Page No:
Part Number
Part Name Line :Bolster EQ Bolster
Cavities
Spiking frame
Cavities
234 1
Granulator
Cooling stand
White
GreenWhite
1 2
3
4
5
Time:
Standardized Work