Getting Started With Kanban
Introducing Kanban Into Your Facility
Kanban is usually introduced gradually
and typically may involve some trial and error.
1. The first step is to become
familiar with Kanban and the options it offers. Some
parts of Kanban may be suitable for your company, others
may not.
This tutorial is just a brief overview
of Kanban. Becoming familiar with Kanban will requiring
in-depth reading, possibly attending a seminar or hiring
a consultant.
2. Select the components of Kanban
that will work in your facility. Not all parts of Kanban
may be appropriate for the types of products you produce.
Kanban may be appropriate for one product, and not for
another. In some cases a simple manual Kanban will work
well. In other cases computer automation of Kanbans
may be the best option.
You will need to evaluate both your
in-house production and your suppliers in order to determine
which Kanban options will benefit your facility.
3. Plan your Kanban system.
Kanban involves more than just manufacturing. Other
functions such as purchasing, warehousing, shipping/receiving,
quality control, transportation, accounts payable and
engineering will be involved. Include all of those who
will be effected in your Kanban planning and design
process.
In planning, keep in kind that your
object to to have what is needed (supplies, parts, manpower,
information, energy, equipment, etc.), where it is needed
when it is needed.
4. Set goals for Kanban. Based
on your plan, set a schedule with measurable goals.
What do you want Kanban to accomplish and when should
that goal be reached? Determine what will be measured,
and how it will be measured. Be sure to get baseline
measurements of your current manufacturing system and
inventory levels, before Kanban is implemented.
5. Begin implementation of Kanban.
A common approach to implementing Kanban is to start
with a generous number of Kanbans - containers, pallets,
boxes, etc. Then systematically reduce the number of
containers until the point at which the supply of materials
is just in balance with the rate of use is reached.
As containers are removed from the process, it will
eventually reach the point at which production is delayed
because the next container has not yet arrived. At this
point add one container to the system to bring it back
into balance.
In using this trial and error approach,
be sure a safety stock is available so that production
is not interrupted. You identify the point at which
there is one too few containers as the point at which
material from the safety stock is used.
This trial and error approach should
be spread over a significant period of time to allow
for normal fluctuations in production. In other words,
don't remove a container every thirty minutes. Instead,
remove a container once a day, or even once a week.
Container Identification
It is important that containers are
clearly identified. Workers should be able to immediately
identify the contents of a container just by looking
at it. Color coding and labeling
containers is an effective approach. For example,
paint pallets or containers different colors so that
each color is associated with one component or part.
Use large labels, that are easy to read from a distance,
making it easy for anyone to identify the contents of
a pallet or container. In addition to color coding your
containers, use the same color code for your labels.
Label materials are available in a wide variety of colors,
giving you flexibility in color coding Kanban containers.
Learn More About Kanban
Getting Started with Kanban by Steve
Hudgik
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