kanban

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Related to kanbans: Mass customization, Jidoka

Kanban

A scheduling system indicating how many goods one must produce in a given period of time, how one must produce them, and by when they must be completed. It developed in Japan as a means to achieve just-in-time inventory control.

kanban

a Japanese term meaning ‘card’. It is used to describe part of the control mechanism for JUST-IN-TIME (JIT) and is at the centre of all JIT operations. A kanban is used to authorize the previous stage of production to make components. As such the system operates as a pull mechanism. A kanban system, to work successfully, should operate within the following conditions.
  1. A relatively stable demand pattern, with probably no more than 10% variation either side of the average.
  2. QUALITY is imperative, defects for components in the system must be at a minimum. This is because kanbans normally work at preset component levels.
  3. Good operator motivation. This is essential because a kanban is essentially a short-term, minute by minute inventory control mechanism. The simplest kanban is known as the kanban square. Here a square card (hence the name) is placed between two workstations. When the square is full (to a preset level) work at the previous station stops. When work is pulled from the square by the next operation (hence the alternative term ‘pull-system’) then work at the previous operation may start again. Kanbans exist in a number of variations, as stationary points attached to a work centre or as cards attached to an inventory bin, the principal remains the same however. See LEAN MANUFACTURING.
References in periodicals archive ?
Algunos metodos, como los ofrecidos por la Manufactura Esbelta (2), permiten crear nuevas formas de trabajo, donde el Kanban es una de las herramientas de la Manufactura Esbelta que permite identificar, corregir y optimizar el proceso de produccion basado en un sistema de instrucciones de comunicacion de manera sencilla (Ortiz, 2011; Visbal 2012), lo cual busca eliminar toda actividad que no agregue valor al producto.
These are set up on a Kanban system for direct replenishment, rather than kitted and de-kitted for individual jobs.
In pull-based SCs, such as Kanban systems, production and distribution decisions are based on true customer demand rather than forecasted demand and SC members do not hold any excess inventory and only respond to specific orders.
Used improperly kanban can run you out of product and cause you to miss critical delivery dates, so it's important to start small and choose parts or items that you know that you can quickly replenish in a matter of hours or a couple of days if an emergency were to arise.
Steiner: We only replenish Kanban levels that certain customers pull from, and in these instances the stockpiling costs are born by the customer.
Using a kanban system, pull scheduling smoothes the flow of materials across a factory floor because production signals are generated real-time for components as work-in-process inventories are consumed in downstream workstations.
Recently, researchers have presented many results and conjectures that provide some insight in the allocation of kanbans. We highlight some of the more important studies that deal with allocating a given total number of kanbans, N, over a given number of workstations, M.
The amount of WIP on the floor is controlled through the use of kanbans. Kanbans are used to trigger what is to be built, when to build it and how much should be built.
With origins in the Japanese card controlled inventory system called kanban (meaning signboard in Japanese), JIT techniques were initially confined to the area of inventory control.
In this reported system, MRP orders and kanbans are both used as production triggering signals.
In this study, a simulation based model is developed using Rockwell Arena Software (3) to investigate the performance of a Kanban-based automated production system with the purpose of analysing the effect of demand variability, service time variability and the number of Kanbans on the performance measures such as throughput, waiting queue lengths, work-in-process inventory, utilization etc.