Contents

What is KANBAN? Introduction about KANBAN. KANBAN Procedure at Gear Line.

KANBAN Flow Chart. Process Layout. KANBAN walk around Sequence Chart.

KANBAN Planning Module with Example.

Ground Rules. KANBAN Planning Flow Chart. Planning example.

Benefits of KANBAN. KANBAN monitoring Check Points.

What is KANBAN?
Kanban System is an information system that harmoniously controls the production of the necessary products in the necessary quantities at the necessary time in every process of a factory and also among companies. A Kanban is a tool to achieve JIT production.

Introduction about KANBAN

Coined from the Japanese word kan which means card, and ban which means signal, kanban is simply described as a system for pull production control. When we talk of pull, it is more of a control measure to release materials into production only when they are needed. On the other hand, the push system is a transposition of the pull production system. Push is thereby releasing materials into production as customers orders are processed and the materials become available. Material Requirement Planning or Manufacturing Resource Planning (MRP) modules are typical push systems. Some may say that Kanban is more of a visual scheduling system. The emphasis here is that Kanban is not a system where everything is put on schedule, it must be made clear that Kanban is a production control system intended to enable the process owner to easily view production requirements and ensure that parts or supplies are ordered/procured only if necessary. Kanban is generally used in two instructional forms: 1. A simple production instruction (shikake) indicating what, where and when it is needed, and where materials are coming from or going to; and 2. The other form is for parts withdrawal (hikitori) or an illustrated piece to visually communicate materials that have been consumed and their quantities that need to be replaced by upstream processes. The purpose of Kanban is, therefore, to automate the inventory controls without the need of analysis or planning.

KANBAN Procedure at HHP Grinding Module

HHP Grinding Module KANBAN Flow Chart

KANBAN Procedure at HHP Grinding Module

There are 2 colors of KANBANs in Gear line.

Green KANBAN Pink KANBAN Yellow KANBAN Orange KANBAN - Instructions for issuing IP(Shot blasting output) on Jr-4. - Instructions for issuing IP on journal. - Instructions for Heat Treatment. - Instructions for Hard Grinding.

Each KANBAN means transaction of 10 components. Green & pink color KANBANs are to be scheduled on KB posts in Gears Soft. Yellow color KANBANs are to be scheduled on KB posts in HT. Orange color KANBANs are to be scheduled on KB posts in Hard Grinding. All the scheduling shall be done as per respective timings in each area. The procedure for scheduling of KANBANs is as followsCollect the KANBANs from collection boxes of all the cells in Soft, HT & Grinding. Green KANBANs shall be available from Gears Soft. Pink KANBANs will be available from HT. Yellow KANBANs will be available from hard Grinding. And Orange KANBANs will be available from FG Stores. Place these KANBANs part no. wise in the PPC KANBAN rack. Take out the KANBANs part no. wise from the rack as per KANBAN plan. Schedule all the four colored KANBANs in respective areas as per point nos. 3, 4 & 5 above. While scheduling, if already KANBANs are present in that shift on KB post, remove them and keep them as pending production in the last hook of deep night shift.
At any stage, the no. of KANBANs recd. in collection boxes is the production against the KB plan scheduling. Any mutilated KANBANs are to be returned to PPC who will in turn issue new KANBAN of the same color.

KANBAN Procedure at Gear Line

Production will receive the turned blanks as per KANBAN plan with Green KANBANs and in orange trolley. 2. The Green KANBAN is at the end of the arm in each arm & over that 10 blanks are kept. Operator, after machining 10 components, takes out the green KANBAN from the trolley & puts it in the collection box given on every KB board. And at the same time removes 1 pink KANBAN from the board & puts in green color trolley meant for within cell movement of components. 3. After completing all the operations, the trolley along with pink KANBANs & Components & ALMAP tag is kept in mini mkt. 1 in blue color trolleys. Empty blue trolleys are supplied by PPC at specified area. 4. PPC as per the KANBAN plan, moves the material in multiples of 10 and along with pink KANBANs & in blue color trolleys, to HT for heat treatment. 5. HT, as per KANBAN plan, loads the components in furnaces & puts the released pink KANBANs in collection box. 6. After heat treating the components, HT puts on yellow KANBANs & moves the material in mini mkt. 2 7. PPC again as per KANBAN plan moves the material in multiples of 10 and along with yellow KANBANs & in blue color trolleys, for bore grinding. 8. After completing all the grinding operations, orange KANBANs are put on & then finished material is moved to stores in available empty orange trolleys. Empty orange trolleys are supplied by PPC at passing area. Released yellow KANBANs are put by heat treatment dept. in collection box. From stores, material is issued to GB assly. as per GB assly. plan. 9. All the released KANBANs are collected by PPC & kept is KANBAN rack for scheduling of next shift.

KANBAN Procedure at Gear Line

As per KANBAN flow chart of Gear Line, the process is explained as followsThe information flow with KANBANs & physical material flow are shown in different color arrows in the slide. Information flow is always backwards with different color KANBANs and physical material flow is always forward. This flow can be explained with one example of 071 gear. Suppose, 100 nos. of finished gear have been withdrawn from FG Buffer and consumed for GB assly, then a requirement of 100 nos. is created in FG buffer because it is to be maintained for 3 days FG stock. Thus, 10 orange KANBANs of 071 are scheduled on Hard Grinding KANBAN board which is an instruction for them to produce 100 nos. of 071 gear & pass to FG buffer so as to maintain the FG stock. Now, to produce 100 nos. of 071, hard material is required which is shifted from mini mkt. 2 to hard grinding by PPC. Here again, to maintain the mini mkt. stock to 3 days, a requirement of 100 nos. of 071 is created in mini mkt. 2. Hence, the information is flown backwards through yellow KANBANs to HT to heat treat 100 nos. of 071 & push to mini mkt.2. To heat treat, HT will require 100 nos. of 071 soft material which will be again supplied by PPC from soft mini mkt. 1. Similarly, a requirement of 100 nos. is created in soft mini mkt. 1 which will be filled up by gear soft production against the pink KANBANs scheduled on their board by PPC. For producing these 100 nos. in soft, 100 nos. of turned blanks will be required from stores. This trigger is generated by green KANBANs. Thus, stores issue the turned blanks physically with green KANBANs to gear soft line.

KANBAN Procedure at Gear Line

Gear KANBAN Process Layout

Ground rules between PPC & Production for releasing items requirement Plan and KANBAN Plan
Expected passing figs will be given by production. For the current month by 25th. Items requirement plan for first 10 days of next month will be released on 26th of previous month. Commitment against first 10 days requirement plan will be given by production on 28th of the month. This commitment is verified by PPC for suitability with requirement. Commitment (Mfg. Plan) is uploaded in ALMAP on 28th evening. Items requirement plan for next 20 days is given on 6th of that month. Commitment against these 20 days requirement plan will be given by production on 8th of the month. This commitment is verified by PPC for suitability with requirement. Commitment (Mfg. Plan) is uploaded in ALMAP on 8th evening. From this commitment given by hard line, Send To HT plan is prepared. Then considering this send to HT plan as base, shaving plan is derived and subsequently cell machining planning is done.

PPC Planning Procedure Chart (KANBAN)

START

- Mid PPM meeting on 17th. - Month beginning PPM on 4th.

GB Synopsis rec. from MPS (Weekwise GB

- Synopsis - Opening FG stock of Gear Boxes.

Datewise GB assly. plan

- Datewise GB assly. plan. - Opening Stock, GB, SPD, CKD requirements - 3 Days finish buffer stock - Manpower availability - Capacity of Production in Soft & Hard.

Datewise compo. requirement Plan

- Total minimum qty. required for GB assly. & SPD to be fulfilled. - Datewise component requirement plan. - Commitment from Production being verified by PPC for suitability with requirement & then ported in ALMAP.

Commitment from Production Lines Mfg. Plan

KANBAN PLANNING

- Base as Mfg. Plan. - Opening WIP in grinding stage. - Grinding Capacity 320 sets / day - Mini mkt 2 stock + Hard WIP in HT (Shot peening & Furnaces) - Planning is done along with Prod. rep.

Grinding Plan

Return From HT after 48 hrs.

A B

A
- Base as Grinding Plan. - Mini mkt 2 stock (2-3 days) - HT Capacity is considered 289/day on 25 days basis. And 320/Day on 30 days basis. - Plan is uploaded in ALMAP for monitoring.

B
Send To HT Plan

- Base as Send To HT Plan. - Capacity of machine. - Mini mkt. 1 & Mini mkt. 2 stock (2-3 days in each)

Shaving Plan

- Base as Shaving Plan. - Cell machining Capacity 300 sets / day. - Mini mkt. 1 & Mini mkt. 2 stock (2-3 days in each) - Turn Blank / Forgings availabilty. - Cell m/c = Bal. Plan + MM1 + MM2 WIP(Soft+Hard) - Planning is done along with Prod. rep.

Cell Machining Plan

Issue from Stores

BENEFITS OF KANBAN

1. Reduction in Stock out situation (Forced idle time due to material unavailability) on the machine / Assy line 2. Smooth material flow throughout the processes 3. Awareness about the production plan at the associate level

4. Elimination of unplanned setup changes

5. Controlled WIP inventory 6. Easy traceability of rejections 7. Improved house keeping