KANBAN Study

BFL

CONTENTS

- Need for KANBAN at BFL

- What is KANBAN
- KANBAN System An Overview

- Benefits
- Implementation steps Summary - KANBAN walk

Need for KANBAN

Soft Module Capacity: 1200 parts/month

Grinding Module Capacity: 940 parts/month

Final Module Capacity: 1500 parts/month

Dispatching

GRINDING OPERATION WAS THE BOTTLENECK

* On a 3-shift basis

The River Analogy

CONTENTS

- Need for KANBAN at ALB

- What is KANBAN
- KANBAN System An Overview

- Benefits
- Implementation steps Summary - KANBAN walk

KANBAN DEFINED
Kanban System is an information system that harmoniously controls the production of the right products in right quantities at right time in every process of a factory and also among companies.

OBJECTIVES OF KANBAN
There are four objectives of KANBAN 1.Convey information (what and when to produce, when and where to move) 2.Control inventory (fixed total quantity of parts)

3.Control process (visual are Kanban moving?)

4.Support improvement (gradually reduce no. of Kanban)

TYPES OF KANBAN

CONTENTS

- Need for KANBAN at ALB

- What is KANBAN
- KANBAN System An Overview

- Benefits
- Implementation steps Summary - KANBAN walk

KANBAN AS IMPLEMENTED IN GEARS

A Mix of Production instruction and parts withdrawal Kanban

Is designed to reduce Forced idle time due to No Material

System owner is PPC, works in co-ordination with production Trigger is based on PPC plan at component-machine level

Considerations while preparing Production Plan

PPC will develop and control the production schedule starting with the final operation (J7/J9) Capacity variations at each stage i.e. Jr-4, Pin-1&2 & Jr-3. Manpower availability. Variety of Dies. Maintaining of Mini Mkt. stock for avoiding the stock out situation for Jr-4. WIP norms Availability of Shot Blasting output

KANBAN METHODOLOGY
PPC makes the date wise and shift wise KANBAN plan as per the date wise Mfg Plan. As per the KANBAN plan, scheduling is done on KB posts in Grinding Module Material is made available for machining, 1 shift in advance at the appropriate machines. Production, produce the components and attach KANBANs to them as per color coding in respective lines. PPC moves the material with KANBANs.

KANBAN Card Samples

WITHDRAWAL KANBAN Part No. Part Name F1607811 3rd on MS Trolley type No. of pcs Storage Location Point of use A 10 Turn Blank Store 3rd on MS Cell D-3306

Crank Shaft

3
Jr. Semi Finish

PART VISUAL

PRODUCTION KANBAN Part No. Part Name F1607811 3rd on MS Trolley type No. of pcs A 10 Part No. Part Name

PRODUCTION KANBAN F1607811 3rd on MS Trolley type No. of pcs

A B
10

PART VISUAL

SOFT MACHINING

PART VISUAL

HARD MACHINNG

KANBAN Card Samples

A 3 Jr. Semi Finish

D-3306 Crank Shaft

PRODUCTION KANBAN Part No. Part Name F1607811 3rd on MS Trolley type No. of pcs A 10 Part No. Part Name

PRODUCTION KANBAN F1607811 3rd on MS Trolley type No. of pcs

A B
10

PART VISUAL

SOFT MACHINING

PART VISUAL

HARD MACHINNG

KANBAN POST
Grinding Module Die No3306/3307/3295
Production Area Description Production Schedule

Key Timings

KANBAN Procedure Kanban drop box

Kanban Post is used as visual display for triggering Production.

KANBAN Trolley distribution

KEY TIMINGS

CONTENTS

- Need for KANBAN at ALB

- What is KANBAN
- KANBAN System An Overview

- Benefits
- Implementation steps Summary

KANBAN IMPLEMENTATION STEPS (1/2)

Step Decision of Material Information flow Design of the Kanban resources Calculations of Resources Details Study of existing flow, identify stages Decide the flow type and flow stages

Decide mini-markets stages and sizes

Cards color and format Trolley type and color Stores for card Calculate the requirement of the following Cards & its Storage Trolleys Kanban boards and posts Collection boxes Mini-market areas Input material area Kanban post physical location Material flow routes Weekly micro level planning of M/C Loading Key timings for material movement Batch sizes for material movement

Decision of layout

Decision on Kanban Mechanics

KANBAN IMPLEMENTATION STEPS (2/2)

Step Decision on Kanban Mechanics Training of executives and associates Details Weekly micro level planning of M/C Loading Key timings for material movement

Batch sizes for material movement

Train line executives and associates Train associated lines executives and associates Train material handlers

Prepare roll-out plan Order resources as per rollout plan Monitor and improve

Prepare rollout plan, stage-wise is preferable Order resources

Monitoring by Daily checks Periodic audits Problem solving and moving ahead

Roll out in other areas

CONTENTS

- Need for KANBAN at ALB

- What is KANBAN
- KANBAN System An Overview

- Benefits
- Implementation steps Summary

KANBAN METHODOLOGY
KANBAN BOARD will made available near to Jr-4 & Jr-3. KANBAN BOARD will contain two cards with different colors, one card (Production card) will authorizes production on Jr-4 & another card (Move card) authorizes movement of pallet containing Jr-3 output parts to supermarket while moving pallet to supermarket need to detach production card Jr-4 begin to produce another standard pallet to replace the one that was just taken. Production card on Jr-4 need to be planned for SF & J7/J9 after completion of every 36 parts.

KANBAN METHODOLOGY
No of move card depends on set-up change on Jr4 (SF to J7/J9), because when set-up changes Jr-3 output will be consumed by Jr-4. When IP for J7/J9 were moved from supermarket & consumed on Jr-4 operator will need remove the move card and need to keep in drop box available on KANBAN BOARD. Material handler returns cards to appropriate KANBAN BOARD.

KANBAN METHODOLOGY
INFORMATION FLOW

Supermarket

Supermarket

Jr-4 (SF)

Pin1&Pin2

Jr-3

Jr-4 (J7/J9)

MATERIAL FLOW
Move Card Production Card

Thank You