Supplier kanban
rotates between the factory and suppliers
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Common Techniques for Reducing Setup Time
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Common Techniques for Reducing Setup Time (cont.)
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Production kanban
authorizes production of goods
Withdrawal kanban
authorizes movement of goods
Kanban square
a marked area designated to hold items
Q-R
Bin 2 R
b) Kanban inventory system Kanban
R
Q = order quantity R = reorder point - demand during lead time
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Types of Kanban
goods
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Sample Kanban
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Origin of Kanban
a) Two-bin inventory system Bin 1
Reorder card
Internal setup
Can be performed only when a process is stopped
External setup
Can be performed in advance
SMED Principles
Separate internal setup from external setup
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Components of Lead Time
Processing time
Reduce number of items or improve efficiency
Move time
Reduce distances, simplify movements, standardize routings
Copyright 2006 John Wiley & Sons, Inc.Biblioteka Signal kanban
a triangular kanban used to signal production at the previous workstation
Material kanban
used to order material in advance of a process
on each other
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▪ Inventory Hides Problems
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▪ Less Inventory Exposes Problems
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Lean Production
Doing more with less inventory, fewer workers, less space
Just-in-time (JIT)
smoothing the flow of material to arrive just as it is needed
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Waste in Operations
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Waste in Operations (cont.)
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Waste in Operations (cont.)
maintenance Supplier networks
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Flexible Resources
Multifunctional workers
perform more than one job general-purpose machines perform
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Pull System
Material is pulled through the system when needed
Reversal of traditional push system where material is pushed according to a schedule
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Small Lots
Require less space and capital investment
Move processes closer together Make quality problems easier to
detect Make processes more dependent
Cli精ck益to生ed产it 培Ma训st课er 程title style
Click to edit Master subtitle style
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Lecture Outline
Basic Elements of Lean Production Benefits of Lean Production Implementing Lean Production Lean Services
comprised of dissimilar machines brought together to manufacture a family of parts
Cycle time is adjusted to match takt time by changing worker paths
dL + S (150 x 0.5) + 7.5
N= C =
25
75 + 7.5
=
= 3.3 kanbans or containers
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Round up to 4 (to allow some slack) or down to 3 (to force improvement)
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Determining Number of Kanbans
average demand during lead time + safety stock
No. of Kanbans =
container size
where
dL + S N= C
N = number of kanbans or containers d = average demand over some time period L = lead time to replenish an order S = safety stock C = container size
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Basic Elements
Flexible resources Cellular layouts Pull production system Kanban production control Small lot production Quick setups Uniform production levels Total productive
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Standard Operating Routine for a Worker
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Cellular Layouts
Manufacturing cells
Forces cooperation Prevent over and underproduction While push systems rely on a predetermined
schedule, pull systems rely on customer requests
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Copyright 2006 John Wiley & Sons, Inc.