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    Course - Materials Handling: Topic - Kanban System

    Uploaded by

    Anwar
    The document discusses the Kanban system, a pull-based manufacturing process used by Toyota. It originated from Taiichi Ohno after visiting a Piggly Wiggly supermarket and seeing how inventory was replenished based on visual signals. Kanban uses physical or electronic cards to signal the need to replenish materials and regulates supply through a three-bin pull system and Toyota's six rules. The benefits are improved responsiveness, efficiency and reduced costs, while limitations include potential misunderstandings and line stoppages impacting the whole system.

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    Course - Materials Handling: Topic - Kanban System

    Uploaded by

    Anwar
    32 views13 pages
    The document discusses the Kanban system, a pull-based manufacturing process used by Toyota. It originated from Taiichi Ohno after visiting a Piggly Wiggly supermarket and seeing how inventory was replenished based on visual signals. Kanban uses physical or electronic cards to signal the need to replenish materials and regulates supply through a three-bin pull system and Toyota's six rules. The benefits are improved responsiveness, efficiency and reduced costs, while limitations include potential misunderstandings and line stoppages impacting the whole system.

    Original Description:

    Kanban definition, types benefits and disadvantages misconceptions

    Original Title

    Kanban

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    The document discusses the Kanban system, a pull-based manufacturing process used by Toyota. It originated from Taiichi Ohno after visiting a Piggly Wiggly supermarket and seeing how inventory was replenished based on visual signals. Kanban uses physical or electronic cards to signal the need to replenish materials and regulates supply through a three-bin pull system and Toyota's six rules. The benefits are improved responsiveness, efficiency and reduced costs, while limitations include potential misunderstandings and line stoppages impacting the whole system.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    32 views13 pages

    Course - Materials Handling: Topic - Kanban System

    Uploaded by

    Anwar
    The document discusses the Kanban system, a pull-based manufacturing process used by Toyota. It originated from Taiichi Ohno after visiting a Piggly Wiggly supermarket and seeing how inventory was replenished based on visual signals. Kanban uses physical or electronic cards to signal the need to replenish materials and regulates supply through a three-bin pull system and Toyota's six rules. The benefits are improved responsiveness, efficiency and reduced costs, while limitations include potential misunderstandings and line stoppages impacting the whole system.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 13

    Course - Materials Handling

    Topic – Kanban System

    1
    Agenda

    • Introduction
    • Origin
    • Operations
    1. Toyota Six Rules (Done by Meraj)
    2. Kanban Cards, Three bin System (Done by Meraj, Delete it after verify seq.)
    3. Electronic System
    • Types of Kanban
    • Conclusion
    • Reference
    Introduction

    When you
    need?
    • Rough Translation : “Card You Can See”
    • Visual Signal to trigger an action

    Manufacturing System in which the supply of components is


    regulated through the use of an Instruction card (KANBAN) sent
    along the production line.

    3
    Origin

    • Developed by Toyota Engineer Taiichi Ohno


    • Inspired by visit to an American Supermarket Piggly Wiggly.
    Shelves were stocked
    with enough products
    to meet the customer
    demand

    Inventory would be
    restocked when there
    was a Visual Signal

    4
    Operations in Kanban System

    Toyota six rules

    Master in Industrial Engineering


    Summer Semester 2019
    Kanban Card & Three bin system

    Physical Kanban Card

    Digital Kanban Card


    Front Side of Kanban Card Back Side of Kanban Card

    Master in Industrial Engineering


    Summer Semester 2019
    Types of Kanban Systems
    When to Move

    Customer In-House
    Emergency
    Withdrawal Withdrawal Where to Move
    Kanban
    Kanban Kanban
    How to Move

    Suppliers
    Production Storage
    Withdrawal
    Kanban Kanban
    Kanban
    Flow of Kanban Systems

    Supplier Kanban Movable Kanban Production Kanban Movable Kanban Customer Kanban

    External Internal Raw Production Planning Plant FG External


    Supplier Material Flow Unit Team Store Customer

    If Need to Store Parts When Required for Production


    Storage (W.P)
    Kanban flow
    Simple Electronic Kanban Process

    Control the Optimise


    System Processes

    Monitor
    Scan Kanbans
    Inventory
    Multisite Cloud

    Eliminates manual entry errors and lost cards


    Enables real-time demand signaling

    Better tracking of replenishment times


    Benefits Limitations
    • Misinterpretations – sometimes visual signs may be
    misunderstood.
    • Improves responsiveness to changes in • A breakdown at any point in the line can cause entire
    demand. shutdown.
    • Focused and continuous delivery.
    • Increased efficiency of operations.
    • Reducing stock levels and overhead
    costs.
    • Reduction of wastage.

    12
    Misunderstanding Kanban
    X With Kanban you don’t use iterations or iteration’s not possible.
     With Kanban iterations are possible.

    X With Kanban you don’t estimate.


     With Kanban demand fluctuation are estimated and easy to overcome the bottlenecks as the system is
    pull type.

    X Kanban is better than other tools or replacement to other tools.


     Kanban is just a process implemented in parallel to other manufacturing methods and is all about about
    managing workflow or materials.

    13

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