KANBAN

Sanjay Choudhari
Indian Institute of Management
Indore

KANBAN

Japaneses signboard
Method Toyota used for implementing JIT
Each work station has a fixed # kanbans.
In order to produce, you need both material to
work on, and an available kanban.

KANBAN Control
Two kinds of information required at each
process:
When to produce an item?
When to transfer an item one process to next
process?
KANBAN cards instruct workers to produce or
transfer parts

How does a KANBAN card work?

Important operating rules
Always attach the KB card to the part that is
produced or transferred.
If all KB cards are attached, do nothing at this
operation.
KANBAN ensures that
There is no over-production of parts.
No allowance for defective parts.
Defective parts cant be passed on to subsequent
process.

KANBAN
Flow of work
2

How is this Different?

Processes can become idled (blocked) or starved
This makes you painfully aware of problems in
your system.
Material moves through the system so quickly no
in-process recordkeeping is needed.

Importance of Flow
Ohno.

Kanban is a tool for realizing just-in-time. For

this tool to work fairly well, the process must be
managed to flow as much as possible. This is
really the basic condition. Other important
conditions are leveling the product as much as
possible, and always working in accordance
with standard work methods.

Elements of KANBAN
1.
2.
3.
4.
5.
6.
7.
8.
9.

Work Centers
Inbound Stockpoint / Wc
Outbound Stockpoint / Wc
Material Handling System
Standard Size Containers
Part Number
Fixed Daily Production Schedule
Withdrawal Card (Part # , Source Wc ,Destination Wc)
Production Card (Part # , Using Wc)

KANBAN Rules
1. All containers holding parts must have a card (except
when in process)
2. Following wc must PULL parts from preceding wc
3. Containers must always be full

Other KANBAN Type

Two basic cards
Production Kanban
Withdrawal Kanban

KANBAN system for two production

centers
Production ordering
kanban post

Holding Area
for WC 2

Center 1

Store

Center 2

Production flow

Production ordering Kanban

Withdrawal Kanban

Withdrawal
kanban post

KANBAN system for two production

centers
Production ordering
kanban post

Holding Area
for WC 2
W

Center 1

Production flow

Production ordering Kanban

Withdrawal Kanban

Store

Center 2
W
Withdrawal
kanban post

KANBAN system for two production

centers
Production ordering
kanban post

Holding Area
for WC 2
W

W
P

Center 1

Store

Center 2

Production flow

Production ordering Kanban

Withdrawal Kanban

Withdrawal
kanban post

KANBAN system for two production

centers
Production ordering
kanban post

Holding Area
for WC 2

Center 1

Center 2

Production flow

Production ordering Kanban

Withdrawal Kanban

Withdrawal
kanban post

KANBAN system for two production

centers
Production ordering
kanban post

Holding Area
for WC 2

Center 1

Center 2

Production flow

Production ordering Kanban

Withdrawal Kanban

Withdrawal
kanban post

KANBAN system for two production

centers
Production ordering
kanban post

Holding Area
for WC 2

Center 1

Center 2

Production flow

Production ordering Kanban

Withdrawal Kanban

Withdrawal
kanban post

Store
Shelf No. 5E215

Item Back No.A2-15

Item No. 35670507

FORGING

Item Name DRIVE PINION

Car Type

Preceding Process

SX50BC

B-2
Subsequent Process
MACHINING

Box Capacity
20

Box Type Issued No.

B

4/8

Withdrawal Kanban

M-6

Store
Shelf No/ F26-18 Item Back No. A5-34
Item No. 56790-321

Process
MACHINING
SB-8

Item Name CRANK SHAFT

Car Type

SX50BC-150

Production-ordering Kanban

KANBAN

k = Number of kanban card sets

D = Average number of units demanded over some time period
L = Lead time to replenish an order
S = Safety stock, as a percentage of demand during lead time
C = Container size

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

The Kanban System

Receiving post

Kanban card for

product 1
Kanban card for
product 2

Storage
area

Empty containers
Assembly line 1
O2

O1

Fabrication
cell

O3

O2

Single-Card Kanban System

Assembly line 2
Full containers

Other Kanban Signals

Cards are not the only way to signal need
Container system
Containerless system

Other Kanban Signals