KANBAN SYSTEMS Contents

• INTRODUCTION
Andrew Kusiak
Intelligent Systems Laboratory
• JUST-IN-TIME CONCEPT
2139 Seamans Center • MODELING KANBAN SYSTEMS
The University of Iowa • MODIFIED KANBAN SYSTEMS
Iowa City, Iowa 52242 - 1527
• SUMMARY
Tel: 319 - 335 5934 Fax: 319-335 5669
andrew-kusiak@uiowa.edu
http://www.icaen.uiowa.edu/~ankusiak

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What is JIT? Examples of Waste

Idle machine run

z A management approach Waiting for parts

z Producing only what is needed, at the time it is Counting parts
needed, and the amount needed Overproduction
z An integrated management system Moving parts over long distances
z JIT’s mandate: Eliminate waste Storing inventory
z “Kanban systems” - an example implementation Looking for tools
strategy of the JIT concept Machine breakdown
Rework
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Elements of JIT Pull vs Push System

Push
• Forecast driven
• Pull production concept • Larger lot sizes (based on EOQ)
• Flexible resources
• Cellular manufacturing • Fast response to changes in production demand
• Kanban production control
• Small-lot production Pull
• Quick setups • Demand driven
• High quality • Small lot sizes
• Supplier networks
• Slow response to changes in production demand

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 Kanban Systems
Kanban and Kaizen
Lost its glamour?
Kanban - a card (Japanese term)
The first kanban system was applied by Taiichi Ohno
in Toyota around 1953 to: vs

z Reduce inventory and production cycle time Kaizen - continuous improvement

z Improve productivity • a concept different than Kanban
• problem solving by teams

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Push vs Pull Concept Scheduling Kanaban Systems

Information flow
Material flow
• Each stage has its ‘own schedule’ of kanbans
Production plan
• This schedule is determined at the kanban system
Stage n
design stage
Stage 0 Stage 1 Stage 2 . . . (Final) • Production is indirectly scheduled by kanbans
Schedule
Pull system Production plan
Production plan
Stage 0 Stage 1 Stage 2 . . . Stage n
(Final)
Stage 0 Stage 1 Stage 2 . . . Stage n
(Final)

Schedule Schedule Schedule Schedule Schedule

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Kanban Control System

Kanban Control System
• Kanban card indicates standard quantity
of production
• Derived from two-bin inventory system
• Kanban maintains discipline of pull production
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Intelligent Systems Laboratory
• Once implemented, a Kanban system
acts a control system rather than
a scheduling system
• It implements a repetitive schedule
embedded in the system
• This schedule can be generated by
a scheduling algorithm
• Simulation can be used to determine
the number of kanbans, queue size, etc.
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 Example Kanban The General Kanban System
Op1: When demand from stage i +1 occurs, withdraw
a kanban and place it on the dispatching board.
Part No: 7412
Op2: Production activity initiates when a kanban is
Description: Slip rings placed on the dispatching board.
Op3: Simultaneously, Op2 Op4

Production Send parts with kanbans

Box capacity 25 demand is sent to
stage i -1 Stage i-1 Stage i Stage i+1

From : Box Type A To: Op4: Completed parts Kanban

Machining Assembly with kanbans are Kanban Kanban

M-2 Issue No. 3/5 A-4 sent to stage i + 1. Op3 Withdrawal Withdrawal
Op1
Kanban box
Dispatching board
Material flow
Kanban flow
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Dual Kanban Dual Kanban System

Production kanban - a card authorizing
Withdrawal Staging area Withdrawal Staging area Withdrawal
production of goods Kanbans for process B Kanbans for process C Kanbans

Withdrawal kanban - a card authorizing

Production Production
the movement of goods Process A Kanbans Process B Kanbans Process C

Each kanban is physically attached to

a container

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Basic Kanban Rules

Rule 1: Move a Kanban only when the lot it
? represents is consumed.

Rule 2: No withdrawal of parts without

Is kanaban system a zero in-process a Kanban is allowed.
inventory system? Rule 3: The number of parts issued to the
subsequent process must be the exact number
Close but not exactly! specified by the Kanban.

Rule 4: A Kanban should always be attached

to the physical parts.
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 Basic Kanban Rules Dual Kanban System
P W P
Rule 5: The preceding process should always produce
parts in the quantities withdrawn by the subsequent
process.
Process Process
Rule 6: Defective parts should never be conveyed X A X X B
to the subsequent process. Storage Assembly

Rule 7: Process the Kanbans at every work center

in the order in which they arrive at the work center. W Container with a withdrawal kanban Flow of work
P Container with a production kanban Flow of kanbans
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Dual Kanbans
1. Process B receives a production kanban. It must produce enough of the items
requested to fill the empty container to which the production kanban is attached.

2. Process B uses a container of input items and generates a request for more items
from the preceding workstation (process A).
?
3. The request for more items takes the form of a withdrawal kanban sent
to preceding workstation (process A). Is kanban system a jobshop or flowshop?
4. Since process A has the items available, the withdrawal kanban is attached
to the full container and immediately sent to process B.

5. The production kanban that originally accompanied the full container is removed
and placed on the empty container, therefore generating production at process A.
Flowshop
6. Production at process A requires a container of input items. Process A uses a
container of input items and generates a request for more input from preceding
workstation. The request for more input items takes the form of a withdrawal kanban
sent to the preceding workstation.

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Basic Preconditions for Balanced System

Kanban Systems Schedule
Station
Flow 1 = Flow 2 = Flow 3
• Repetitive production in small lots
S1 Load 1
• Balanced manufacturing system (capacity balancing
S2 Load 2
model)
S3 Load 3
Time
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 Production Balancing
Capacity
Period 3 Balanced System
Period 2 C/90
150% Period 1 B/60 Capacity
100%
A/30
50% A/10
Manufacturing B/20
Time
System Loading 0 10 20 30 100% C/30
Perspective Before production balancing
Capacity

150% C/30 C/30 C/30 Time

0 10 20 30
B/20 B/20 B/20
100%
A/10 A/10 A/10
50%
Time After production balancing
0 10 20 30
Production balancing
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A A A A A A A
.....
Functions of Kanbans
Production system before production balancing
• Visibility function
• Production function
A C C C B B A
• Inventory function

.....

Production system after production balancing

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Kanban Squares
Kanban Racks
X X X 407 409 410 412

Marked area holding

limited number To hold a limited
of output items 408 number of
X items (e.g., 1 or 2)
X X
411

Flow of work
Flow of information

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 Kanban Post Office
Signal Kanban
407
65 66 67 68 69 70 71
408

409 72 73 74 75 76 77 78

79 80 81 82 83 84 85

407 408 409 86 87 88 89 90 91 92

93 94 95 96 97 98 99
Resembles the reorder point system
(order components when inventory drops below
100 101 102 103 104 105 106
the safety level)
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Determining Number of Kanbans

Example
Number of kanbans =
Number of kanbans =
Units daily demand x Order cycle time x Safety factor
Units daily demand x Order cycle time x Safety factor
Lot size
Lot size
400 units per shift
Units daily demand = the daily production rate of .2 shift per part
the part lot size of 20 parts
Order cycle time = the time it takes to process the part 400 x .2 x 1.5
Number of kanbans = = 6
Lot size = the number of parts authorized by the kanban 20
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Classification of Kanbans
Safety Factor (1) Primary kanban: travels from one stage to
another in a main manufacturing cell or
production preparation area
The safety factor is reduced with time (2) Supply kanban: travels from a warehouse or
storage facility to a manufacturing facility
from 1.5 to just-in-time factor of 1.
(3) Procurement kanban: travels from outside of a
company to the receiving area
400 x .2 x 1 (4) Subcontract kanban: travels between
Number of kanbans = = 4 subcontracting units
20 (5) Auxiliary kanban: may take the form of an
express kanban, emergency kanban, or a
kanban for a specific application
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 Production kanban Supply kanban

SNP Part code Inspection

Product name location
Card no.
Due date
SNP
Warehouse
Part code Part name location
Preceding Succeeding
stage stage Card no.

Supplier name SNP Package Inspection type

type
SNP: standard number of parts
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Procurement kanban Auxiliary Equipment

(1) Kanban box: to collect kanbans after their

Part no. Part name withdrawal.
(2) Dispatching board: in which kanbans from the
Storage location Supply succeeding stage are placed in order to
location display the production schedule.
Supply package type
(3) Kanban management system: a system to
manage kanbans.
Card no. (4) Supply management system: a system to
SNP
manage the supply of raw materials.

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General kanban control system Summary

Buffer

Vendor
Procurement
Warehouse

Supply
Types of kanban systems
kanban kanban
Primary Assembly
kanban line
• Single kanban system (using production kanban)
Subcontract
kanban
Buffer
Material flow
• Dual kanban system (using production and
Subassembly line
Buffer Subassembly line
withdrawal kanbans simultaneously)
Information flow

Primary Kanban box

kanban • Semi-dual kanban system (changing production
Assembly shop
Dispatching board kanbans and withdrawal kanbans at intermediate
Assembly line
stages)

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