Kanban

KB001 Kanban A New Approach
Kanban A New Approach (Tool for Information Flow)
Agenda
Time 8:00 AM 8:05 AM 8:20 AM 9:05 AM 9:20 AM 10:05 AM 10:20 AM 11:15 AM 12:15 PM 1:00 PM 2:00 PM 2:45 PM 3:00 PM 4:00 PM 4:45 PM 5:00 PM 5:30 PM 5:45 PM Topic/Activity Opening Introduction Information Flow Break Kanban Simulation1 Break The Customer Leveling Exercise Lunch Kanban Simulation 2 Internal Pull System Break Lot Box Production Lot Size Calculation Break Material Movement Supplier Card Calculation Closing
2
Introductions
Name Years of Service Current Position
Kanban System
Based on Toyota Production System Driven by External Customers
Addresses Constraints & Bottlenecks 1. Understanding our Capabilities 2. Lot Size Production
Overview
Supporting Company Strategy Understanding Customer Needs
Internal Kanban System

Signaling the Supplier
The Objective
Lower Inventory / Reduced Lead-Time
Pull of Product Based on Usage
Create Information System that Supports Lean Principles
Company Strategy
Grow our Business
Internal and external Strengthen our resources
Improve our Competitive Position

Continually strive for perfection Reduce cost Eliminate waste in operations
Supporting Company Strategy

Elimination of Waste
Overproduction Material movement Inventory
Transition to Just-in-Time
Kanban system Kanban signals
Key Assumptions
Production schedules will always change
Production will never go according to schedule It is human nature to overproduce
Offsetting the Assumptions

Kanban System
Withdraw only what you need Replenish what is taken
Overall Benefits
Flexibility in production Prevents overproduction Reduces inventory
10
Information Flow
11
The Kanban Signal

The Kanban signal tells us:
When to make it!
When to move it!
12
Kanban System
Production Card Withdrawal Card
Supplying Process
product product
Customer Process
Finished Goods Store

13
Withdrawal Kanban Signal

Tells us:
When to move What to move Where to move How much to move
14
Three Types of Withdrawal Kanban Signals

Customer Kanban Signal
Transfers material from plant to customer
Move Kanban Signal

Transfers material between work units
Supplier Kanban Signal

Pulls material from supplier to plant
15
Customer Kanban Signal Information

Supplier Quantity Supplier Number Container Type Part Number Description
Card Number
Kanban Signal Number
Storage Location
Storage Address
16

Supplier
Quantity
Supplier No.
Card No.
Kanban Signal No.
Container Type
Part No.
Description
Storage Location
Storage Address
17
Flow of Customer Kanban Signal

Plant
Finished Goods Store External Customer
needed product
18
Move Kanban Signal Information

Part Number Supplier Name Storage Address (Point of Storage) Card Number Kanban Signal Number Work Unit Name (Customer) Quantity per Container Line Address (Point of Use)
19
Move Kanban Signal

STORE ADDRESS WORK UNIT ADDRESS
SUPPLIER NAME
Kanban Signal No. WORK UNIT NAME
PART No.
QUANTITY
CARD #
20
Flow of Move Kanban Signal

Move Kanban Signal
Internal
Raw Material Store Production Work Unit
needed product
21
Supplier Kanban Signal Information

Supplier Name Part Number Part Name Customer Storage Address
Work Unit Address

Quantity per Container Card Number

22

Supplier Name Kanban Signal Number
Part Number
Quantity
Card No.
Part Name Store Address Work Unit Address
Customer
23
Flow of Supplier Kanban Signal

External Supplier
needed product
Internal Raw Material Store
24
Flow of Withdrawal Kanban Signals

Supplier Signal Move Signal Customer Signal
Internal External Supplier

needed product
Internal Production Work needed Unit product
Plant Finished Goods Store External Customer

needed product
Raw Materials Store
needed product
25
Production Kanban Signal

Tells Us:
When to make What to make How much to make
26
Two Types of Production Kanban Signals

Instructs us to make One Container
Signal (Triangle)
Instructs us to produce One Lot Used when a work unit does not have the changeover capability to produce one container for one production card
27
Production Card Information

Store Address Kanban Signal Number
Work Unit Name

Part Number Quantity Card Number
28
Production Card
STORE ADDRESS
Kanban Signal No.
WORK UNIT NAME
PART No.
QUANTITY
CARD #
29
Signal (Triangle) Information

Work Unit Name
Part Number Container Type
Quantity
Process Time Lot Size
Order Point
30
Signal (Triangle)
WORK UNIT PART No. NAME
CONTAINER QUANTITY TYPE
PROCESSING TIME FOR 1 LOT
LOT SIZE
ORDER POINT
# of containers to produce
Where the signal

Kanban Signal #
is placed in inventory
31
Flow of Production Kanban Signals

Production Signal Move Signal Triangle Signal
Internal Sub Assembly Work Unit
needed product
Internal Sub Assembly Work Unit Store
needed product
Internal Final Assembly Work Unit

needed product
32
Kanban Signal Flow

Sub
Assembly Work Unit
Sub Stores
Move
Triangle Kanban Signal
Finished Assembly
Work Unit
33
How Do You Handle Non-Standard Situations

Temporary Kanban Signals Need scheduled down time to PM equipment Sample parts Service parts
34
Temporary Kanban Signal Card

STORE ADDRESS
Kanban Signal No.
WORK UNIT NAME
PART No.
QUANTITY
CARD #
35
Summary of Kanban Types

Withdrawal - Customer Kanban Signal - Move Kanban Signal - Supplier Kanban Signal
Production
- Production Kanban Signal
- Signal (Triangle)
- Temporary Kanban Signal
36
Additional Benefits of Kanban

Support Visual Control
Are we behind? What do I produce first? What is my inventory situation?
Continuous Improvement
Large inventories hide problems Facilitate continuous improvement by removing Kanban Signals
37
Kanban System Simulation
Exercise 1 (Without Leveling)
38
Kanban System Simulation - Exercise 1
Objective
To gain an understanding of Kanban System card transfer, exchange, and loop location
39
Details
Activity will be run in time segments Each time segment consists of one day One truck from customer per day Simulation will run for 5 days
40
Kanban System Simulation - Exercise 1 Activity Pieces
35 Plastic bowls
73 White Lego Blocks
13 Production Cards
8 Move Cards
35 Yellow Lego Blocks

5 Customer Cards
4 Supplier Cards
5 Signal Posts
18 Place Mats
5 Order Cards
41
Activity Layout - Exercise 1

J
Empty Signal Containers Post
1@15
2@15
Empty Signal Containers Post Empty Signal Containers Post
1@15
4 4 4 4
W
Customer
3
Final Assembly
3 3
Sub Assembly
1 1
1 1 1 1
Raw Material Processing
1 1 1 1
Supplier
4 4 4 4
4
A B
4
C
3
3 D
3
3 E
1
1 F 1= G H I
W 2= Y W Y
A - Customer B - Truck Driver-1 (Customer to Plant) C - Final Assembly Operator D - Material Handler-1 (Final Assembly to Sub-Assembly) E - Sub-Assembly Operator F - Material Handler-2 (Sub-Assembly to Raw Material Storage) G - Raw Material Processing (Parts Ordering / Parts Receiving) H - Truck Driver-2 (Plant to Supplier) I - Supplier J - Manager
3=
4=
W W
Y
42
Activity Layout - Exercise 1 Card Types

Empty Containers
Signal Post
Empty Containers
Signal Post
Empty Containers
Signal Post
Empty Containers
Signal Post
Empty Containers
Signal Post
W
Customer
4 4 4 4 4
4 4 4 4 4
Final Assembly
3 3 3 3
3 3 3 3
Production Card
Sub Assembly
1 1 1 1
1 1 1 1
Raw Material Storage
1 1 1 1
Supplier
Production Card
Supplier Card
Production Card
Customer Card
Move Card
Move Card
43
Kanban System Simulation - Exercise 1 Roles

Customer
Receive order from facilitator Move raw materials to customer processing area Remove Customer Cards from container
Place Customer Cards in Signal post

Disassemble lego blocks and place in designated containers Move empty containers to customer empty container storage Repeat above steps for each order
44

Truck Driver 1
Pick up Cards from Signal post Pick up empty containers from customer empty container storage Move empty containers to finished goods empty container storage
Remove Production Cards from finished goods container and replace with Customer Cards
Place Production Cards in final assembly Signal post Move finished goods to customer raw material storage Repeat above steps for each daily order
45
Kanban System Simulation - Exercise 1 Roles Final Assembly Operator

Check final assembly Signal post for production requirements Move raw material container to final assembly processing area Remove sub-assembly and place on final assembly processing area Remove Move Card and place in empty container Move empty container back to final assembly raw materials storage Pick up empty container from finished goods empty container storage and move to final assembly processing area Pick up white processing lego and assemble to sub-assembly and place in finished goods container Pick up Production Card from Signal post and place on finished goods container Move finished goods container to final assembly finished goods storage Repeat above steps for each Kanban Signal
46
Material Handler 1 Pick up Move Cards and empty containers from final assembly raw material storage Place empty containers in sub-assembly empty container storage Remove Production Cards from sub-assembly finished goods and replace with Move Cards Place Production Cards in the sub-assembly Signal post Move finished goods containers to final assembly raw material storage Repeat above steps for each Kanban Signal
47
Kanban System Simulation - Exercise 1 Roles Sub-Assembly Operator

Check sub-assembly Signal post for production requirements Move raw material container to sub-assembly processing area Remove raw material and place on sub-assembly processing area Remove Move Card and place in empty container Move empty container back to sub-assembly raw material storage Pick up empty container from sub-assembly empty container storage and move to sub-assembly processing area Pick up yellow processing lego and assemble to raw material and place in finished goods container Pick up Production Card from Signal post and place on finished goods container Move finished goods container to sub-assembly finished goods storage Repeat above steps for each Kanban Signal
48
Material Handler 2 Pick up Move Cards and empty containers from subassembly raw material storage Place empty containers in raw material empty container storage Remove Supplier Cards from raw material storage and replace with Move Cards Place Supplier Cards in the raw material Signal post Move raw material containers to sub-assembly raw material storage Repeat above steps for each Kanban Signal
49

Raw Material Store (Parts Ordering)
Move empty container from raw material empty container storage to raw material processing Remove Supplier Card from supplier Signal post Place Supplier Card on empty container Repeat above steps for each Kanban Signal Prepare order for shipment
Raw Material Store (Parts Receiving) Move raw material container from raw material receiving to raw
material storage area
50

Truck Driver 2
Pick up empty containers with Supplier Cards from raw material processing area Place empty containers in Suppliers empty container storage Remove Supplier Production Cards from suppliers raw material container and replace with Supplier Cards Place Supplier Production Cards in supplier Signal post Move raw materials from supplier to raw material receiving Repeat above steps for each daily order
51

Supplier
Check Supplier Signal post for production requirements Move empty container from supplier empty container storage to supplier processing area Pick up white processing lego and place in raw material container Pick up Production Card from supplier Signal post and place on raw material container Move raw material container to supplier finished goods storage Repeat above steps for each Kanban Signal
52
Manager
Review the daily production requirements Instruct cells to produce to customer demand or capacity Monitor the production of parts in the value stream Evaluate daily production results
53
Kanban System Simulation - Exercise 1 Customer Orders vs Capacity

Day 1 2 3 4 5 Customer Capacity Actual Production Order Production Hours
Capacity 1 unit = 2hrs 40min 2 units = 5hrs 20min 3 units = 8hrs 00min 4 units = 10hrs 40min
54
The Customer
(Starting Point for a Kanban System)
55
Understanding Customer Needs

Customer Demand
Anticipated Requirements (Forecast)
Takt Time (time required to produce a single part based upon customer usage)
Actual Requirements (Daily Pull)

Leveling
56
Anticipated Requirements
What information do we need?
Customer demand for the month Number of days in demand period
Part Monthly Demand No. of Working Days Daily Demand A 18,000 20 900
Note: 900 units / 2 shifts = 450 units per shift
57
Takt Time
Takt Time = Available Operating Time Pieces
=
=
57,600 - 2,400 900 pcs

61.33 per piece
Sets pace of production to match customer demand

58
Producing to Customer Demand

Production Card Customer Card
Production Work Unit
Customer
59
Customer Ordering History

1600 1400 1200 1000
Units
1600 1400 1200 1000
800 600 400 200 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Day Forecast Actual
800 600 400 200 0
60
Analyze Actual Requirements

Anticipated Demand vs. Actual Demand
Part Anticipated Demand A 18,000
Actual Demand 19,000
Difference 1000
61
Opportunities in Customer Fluctuation

Buffer Stock
Used when demand is in excess of customer forecast Replenished when demand is less than customer forecast
Note: Buffers are an indicator of waste in the system!
62
Leveled Production (Based On 500 Units Of Buffer Stock)

1600 1600
1400
1400
1200
1200
1000
Units
1000
800
800
600 Forecast Actual 200 Production
600
400
400
200
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Day
63
Opportunities in Truck Pitch

Even Truck Pitch
Drives constant Takt Time Reduces fluctuation
Overall Benefit
Reduction in inventory
64
Truck Pitch
Truck 2
Truck 3
Truck 4
Truck 1
6:00
10:00
14:30
16:00
21:00
24:30
= Break = Lunch = Between Shifts
1 - 6:00 2 - 10:00
Truck Times 3 16:00 4 21:00
65
Replenishment Capability
Truck Pick-up Times
1. 6:00 2. 10:00 3. 16:00 4. 21:00
Replenishment Capability Based on Takt Time

21:00 - 24:30 = 3.5 hours = 12,600 seconds 12,600 seconds - 600 seconds (break) = 12,000 seconds 12,000 seconds / 61.33 seconds (takt time) = 195.66 pcs 195.66 pcs / 50 pcs in container = 3.91 containers Truck 1 = 3 containers (45.66 remaining for Truck 2)
66
Leveling Post
Buffer Stock
9 10 11 12 13 14 15 16 17 18
10
500 pcs. used to buffer Customer Orders 50 pcs. per container
10 slots required in Leveling Post for Buffer

67
Leveling Customer Demand

Forecast Leveling Post
P
Production Work Unit Customer
68
Takt Time Post
1st Shift
6 0 0
6 0 6
6 1 2
6 1 8
6 2 4
6 3 0
6 3 6
6 4 2
6 4 8
6 5 4
7 0 0
7 0 6
7 1 2
7 1 8
7 2 4
7 3 0
7 3 6
7 4 2
7 4 8
7 5 4
8 0 0
Line 100
69
Information Required for Takt Time Post

Takt Time = 61.33 seconds Number of pieces per container = 50
Time per container = (Takt Time * Container Quantity) / 60 = (61.33 * 50) / 60 = 51 minutes
(Must deliver a Kanban from the Takt Time Post to the Production Work Unit every 51 minutes)
70
Takt Time Post
1st Shift
6 0 0
6 0 6
6 1 2
6 1 8
6 2 4
6 3 0
6 3 6
6 4 2
6 4 8
6 5 4
7 0 0
7 0 6
7 1 2
7 1 8
7 2 4
7 3 0
7 3 6
7 4 2
7 4 8
7 5 4
8 0 0
Line 100
71
Leveling Customer Demand

Forecast Takt Time Post Leveling Post
P
72
Separating Safety Stock

Distinguish between customer fluctuation and internal problems
Safety Stock inventory amount is based on downtime history
73
Utilizing Safety Stock

Forecast
Takt Time Post
Leveling Post
P
S
74
Leveling
Benefits:
Neutralizes fluctuation from:
Customers orders Truck pitch
Pulls product based on:

Customer usage Takt Time
75
Leveling System
Visual Aid 1 (Neutralizing Customer Fluctuation)
76
Objective
To establish a pull system of production that levels the demand of the customer to meet production capabilities
77
Visual Aid Requirements

Leveling Post
Takt Time Post

Signal Post (20) Customer Cards
(7) Production Cards

(10) Buffer Stock Cards (5) Safety Stock Cards
78
Card Number
To determine the number of Production Cards in the system, take the highest available Cards to be shipped on one truck and add one Card.
EXAMPLE: Truck 4 = 6 Cards 6 Cards + 1 Card = 7 Cards (7) Production Cards Required
Note: Additional Cards may be required for longer lead-times
79
Card Placement
To determine the location of the Production Card on the takt time post, take the available Cards for the last truck and subtract the quantity for the first truck and count backwards from the last truck
EXAMPLE:
Truck 4 - Truck 1 = Cards Generated for 1st (6) - (3) = 3 Cards for 1st Shift
Note: If the number is zero or a negative number, only the last Card of the last truck is generated for 1st shift
80
Visual Aid Layout - Day 1 (End of 2nd Shift)
Leveling Post
1 2 3 4 Buffer Stock
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
81
Visual Aid Layout - Day 2 (6:00 am)
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
82
Visual Aid Layout - Day 2 (6:00 am - continued)
Leveling Post
1 2
4
1 0 0 0
5
1 0 0 6
6
1 0 1 2
7
1 0 1 8
8
1 0 2 4 1 0 3 0
9 10 11 12 13 14 15 16 17 18
1 0 3 6 1 0 4 2 1 0 4 8
1
1 1 4 2 1 1 4 8
2
1 1 5 4
3
1 2 0 0
4
1 2 0 6
5
1 2 1 2 1 2 1 8
6
1 2 2 4
7
1 2 3 0
8
1 2 3 6
9
1 2 4 2
10
1 2 4 8 1 2 5 4
Takt Time Post

1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4
9 9 3 3 0 6
9 9 4 4 2 8
9 5 4
1 1 3 0
1 1 3 6
L L L L L / / / / / T T T T T
5
83
Leveling Post
1 2
4
1 0 0 0
5
1 0 0 6
6
1 0 1 2
7
1 0 1 8
8
1 0 2 4 1 0 3 0
9 10 11 12 13 14 15 16 17 18
1 0 3 6 1 0 4 2 1 0 4 8
1
1 1 4 2 1 1 4 8
2
1 1 5 4
3
1 2 0 0
4
1 2 0 6
5
1 2 1 2 1 2 1 8
6
1 2 2 4
7
1 2 3 0
8
1 2 3 6
9
1 2 4 2
10
1 2 4 8 1 2 5 4
Takt Time Post

1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4
9 9 3 3 0 6
9 9 4 4 2 8
9 5 4
1 1 3 0
1 1 3 6
L L L L L / / / / / T T T T T
B B / / T T
5
84
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

1 1 0 0 0 6 1 1 1 1 2 8 1 2 4 1 3 0 1 3 6 1 4 2 1 4 8 1 5 4 2 0 0 2 0 6 2 1 2 2 1 8 2 2 4 2 3 0 2 3 6 2 4 2 2 4 8 2 5 4 3 0 0 3 0 6 3 1 2 3 1 8 3 2 4 3 3 3 3 0 6 3 4 2 3 4 8 3 5 4 4 0 0 4 0 6 4 1 2 4 1 8 4 2 4
B B / / T T
6
85
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

4 4 3 3 0 6 4 4 4 4 2 8 4 5 4 5 0 0 5 0 6 5 1 2 5 1 8 5 2 4 5 3 0 5 3 6 5 4 2 5 4 8 5 5 4 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 7 0 0 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4
B B / / T T
10
86
Visual Aid Layout - Day 2 (4:00 pm)
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

4 4 3 3 0 6 4 4 4 4 2 8 4 5 4 5 0 0 5 0 6 5 1 2 5 1 8 5 2 4 5 3 0 5 3 6 5 4 2 5 4 8 5 5 4 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 7 0 0 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4
B B / / T T
10
87
Visual Aid Layout - Day 2 (4:00 pm - continued)
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
1
1 0 1 2 1 0 1 8
2
1 0 2 4
3
1 0 3 0
4
1 0 3 6
5
1 0 4 2 1 0 4 8
6
1 0 5 4
7
1 1 0 0
8
1 1 0 6
9
1 1 1 2
10
1 1 1 8 1 1 2 4
Takt Time Post

8 8 0 0 0 6 8 8 1 1 2 8 8 2 4 8 3 0 8 3 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4
1 0 0 0
1 0 0 6
L L L L L / / / / / T T T T T
B B / / T T
11
12
13
14
88
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
1
1 0 1 2 1 0 1 8
2
1 0 2 4
3
1 0 3 0
4
1 0 3 6
5
1 0 4 2 1 0 4 8
6
1 0 5 4
7
1 1 0 0
8
1 1 0 6
9
1 1 1 2
10
1 1 1 8 1 1 2 4
Takt Time Post

8 8 0 0 0 6 8 8 1 1 2 8 8 2 4 8 3 0 8 3 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4
1 0 0 0
1 0 0 6
L L L L L / / / / / T T T T T
B B / / T T
11
12
13
14
89
Leveling Post
1 2
1 1 3 0 1 1 3 6 1 1 4 2
3
1 1 4 8 1 1 5 4
4
1 2 0 0
5
1 2 0 6
6
1 2 1 2
7
1 2 1 8
8
1 2 2 4 1 2 3 0
9 10 11 12 13 14 15 16 17 18
1 2 3 6 1 2 4 2 1 2 4 8
10
Takt Time Post

1 2 5 4 1 0 0 1 0 6 1 1 2 1 1 8 1 2 4 1 3 0 1 3 6 1 4 2 1 4 8 1 5 4 2 2 0 0 0 6 2 1 2 2 1 8 2 2 4 2 3 0 2 3 6 2 4 2 2 4 8 2 5 4
B B / / T T
15
90
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
91
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
92
Visual Aid Layout - Day 2 (End of 2nd Shift - cont.d)
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
93
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
94
Leveling Post
1 2
4
1 0 0 0
5
1 0 0 6
6
1 0 1 2
7
1 0 1 8
8
1 0 2 4 1 0 3 0
9 10 11 12 13 14 15 16 17 18
1 0 3 6 1 0 4 2 1 0 4 8
1
1 1 4 2 1 1 4 8
2
1 1 5 4
3
1 2 0 0
4
1 2 0 6
5
1 2 1 2 1 2 1 8
6
1 2 2 4
7
1 2 3 0
8
1 2 3 6
9
1 2 4 2
10
1 2 4 8 1 2 5 4
Takt Time Post

1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4
9 9 3 3 0 6
9 9 4 4 2 8
9 5 4
1 1 3 0
1 1 3 6
L L L L L / / / / / T T T T T
5
95
Leveling Post
1 2
4
1 0 0 0
5
1 0 0 6
6
1 0 1 2
7
1 0 1 8
8
1 0 2 4 1 0 3 0
9 10 11 12 13 14 15 16 17 18
1 0 3 6 1 0 4 2 1 0 4 8
1
1 1 4 2 1 1 4 8
2
1 1 5 4
3
1 2 0 0
4
1 2 0 6
5
1 2 1 2 1 2 1 8
6
1 2 2 4
7
1 2 3 0
8
1 2 3 6
9
1 2 4 2
10
1 2 4 8 1 2 5 4
Takt Time Post

1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4
9 9 3 3 0 6
9 9 4 4 2 8
9 5 4
1 1 3 0
1 1 3 6
L L L L L / / / / / T T T T T
B B / / T T
5
96
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

1 1 0 0 0 6 1 1 1 1 2 8 1 2 4 1 3 0 1 3 6 1 4 2 1 4 8 1 5 4 2 0 0 2 0 6 2 1 2 2 1 8 2 2 4 2 3 0 2 3 6 2 4 2 2 4 8 2 5 4 3 0 0 3 0 6 3 1 2 3 1 8 3 2 4 3 3 3 3 0 6 3 4 2 3 4 8 3 5 4 4 0 0 4 0 6 4 1 2 4 1 8 4 2 4
B B / / T T
6
97
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

4 4 3 3 0 6 4 4 4 4 2 8 4 5 4 5 0 0 5 0 6 5 1 2 5 1 8 5 2 4 5 3 0 5 3 6 5 4 2 5 4 8 5 5 4 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 7 0 0 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4
B B / / T T
10
98
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

4 4 3 3 0 6 4 4 4 4 2 8 4 5 4 5 0 0 5 0 6 5 1 2 5 1 8 5 2 4 5 3 0 5 3 6 5 4 2 5 4 8 5 5 4 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 7 0 0 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4
B B / / T T
10
99
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
1
1 0 1 2 1 0 1 8
2
1 0 2 4
3
1 0 3 0
4
1 0 3 6
5
1 0 4 2 1 0 4 8
6
1 0 5 4
7
1 1 0 0
8
1 1 0 6
9
1 1 1 2
10
1 1 1 8 1 1 2 4
Takt Time Post

8 8 0 0 0 6 8 8 1 1 2 8 8 2 4 8 3 0 8 3 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4
1 0 0 0
1 0 0 6
L L L L L / / / / / T T T T T
B B / / T T
11
12
13
14
100
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
1
1 0 1 2 1 0 1 8
2
1 0 2 4
3
1 0 3 0
4
1 0 3 6
5
1 0 4 2 1 0 4 8
6
1 0 5 4
7
1 1 0 0
8
1 1 0 6
9
1 1 1 2
10
1 1 1 8 1 1 2 4
Takt Time Post

8 8 0 0 0 6 8 8 1 1 2 8 8 2 4 8 3 0 8 3 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4
1 0 0 0
1 0 0 6
L L L L L / / / / / T T T T T
B B / / T T
11
12
13
14
101
Leveling Post
1 2
1 1 3 0 1 1 3 6 1 1 4 2
3
1 1 4 8 1 1 5 4
4
1 2 0 0
5
1 2 0 6
6
1 2 1 2
7
1 2 1 8
8
1 2 2 4 1 2 3 0
9 10 11 12 13 14 15 16 17 18
1 2 3 6 1 2 4 2 1 2 4 8
10
Takt Time Post

1 2 5 4 1 0 0 1 0 6 1 1 2 1 1 8 1 2 4 1 3 0 1 3 6 1 4 2 1 4 8 1 5 4 2 2 0 0 0 6 2 1 2 2 1 8 2 2 4 2 3 0 2 3 6 2 4 2 2 4 8 2 5 4
B B / / T T
15
102
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
103
Leveling Post
1 2
9 10 11 12 13 14 15 16 17 18
10
Takt Time Post

6 6 0 0 0 6 6 6 1 1 2 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 8 3 3 0 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4
B B / / T T
16
17
18
1
104
Kanban System Simulation
Exercise 2 (With Leveling)
105
Objective
To gain an understanding of the method and benefits of leveling
106
Details
Activity will be run in time segments Each time segment consists of one day One truck from customer per day Simulation will run for 5 days Leveling of production occurs at the Point of Pull
107
Kanban System Simulation - Exercise 2 Activity Pieces 36 Plastic bowls 75 White Lego Blocks 36 Yellow Lego Blocks 5 Customer Cards 11 Production Cards
5 Order Cards
3 Buffer Stock Cards 8 Move Cards 4 Supplier Cards
5 Signal Posts
1 Leveling Post
18 Place Mats
108
Activity Layout - Exercise 2

Leveling Post
1@15
2@15
Empty Signal Containers Post Empty Signal Containers Post
1@15
4 4 W
Customer
4 4 4 4 4 4 B C
Final Assembly
3 3 3 3 D
3 3 3 3 E J
Sub Assembly
1 1 1 1
1 1 1 1
1 1 1 1
Supplier
4 4 4
Y A
F 1=
A - Customer B - Truck Driver-1 (Customer to Plant) C - Final Assembly Operator D - Material Handler-1 (Final Assembly to Sub-Assembly) E - Sub-Assembly Operator 3= F - Material Handler-2 (Sub-Assembly to Raw Material Storage) G - Raw Material Processing (Parts Ordering / Parts Receiving) H - Truck Driver-2 (Plant to Supplier) I - Supplier J - Manager
W 2= Y W 4= W W Y
109
Activity Layout - Exercise 2 Card Types

Leveling Post
Empty Containers
Signal Post
Empty Containers
Signal Post
Empty Containers
Signal Post
Empty Containers
Signal Post
Empty Containers
Signal Post
4 4 W
Customer
4 4 4 4 4 4
Final Assembly
3 3 3 3
3 3 3 3
Production Cards
Sub Assembly
1 1 1 1
1 1 1 1
1 1 1 1
Supplier
4 4 4
(3) Production Cards (3) Buffer Stock Cards
Supplier Cards
Production Cards
Customer Cards
Move Cards
Move Cards
110

Following Roles Same As Exercise 1
Customer Final Assembly Operator Material Handler 1
Sub-Assembly Operator
Material Handler 2 Raw Material Store Truck Driver 2 Supplier
111
Kanban System Simulation - Exercise 2 Roles Truck Driver 1

Pick up Customer Cards from Customer Signal post Pick up empty containers from customer empty container storage Move empty containers to finished goods empty container storage Place Customer Cards in leveling post Remove Cards from leveling post after leveling
Remove Production Cards from finished goods container and replace with Customer Cards Place Production Cards, and/or Buffer Stock Cards if required, in final assembly Signal post Move finished goods to customer raw material storage Repeat above steps for each daily order
112

Manager
Focus on improving operations
113
Kanban System Simulation - Exercise 2 Customer Orders vs Capacity

Day 1 2 3 4 5
Capacity 1 unit = 2hrs 40min 2 units = 5hrs 20min 3 units = 8hrs 00min 4 units = 10hrs 40min
Customer Capacity Actual Production Order Production Hours
114
(Operating The Internal System)
115

Production Instruction
Production Card Signal (Triangle)
Material Movement
Move Card Delivery system
116
Kanban Signal Tool To Trigger Production

Production Card
High level of capability in the work unit
Production of parts in any order
117
Producing Card for Card

If a work unit can produce parts in the same order that they are pulled from stores, then they produce Card for Card The Production Card (typically a white card) is attached to the container after production When a container is pulled from the work unit store, the card is removed and sent back to the work unit to trigger production
118
Points to Remember
The Production Card is the signal to produce a container of a particular part number The work unit produces in the order that the Production Cards are received Changeover time must be equal to or less than the consumers changeover time
119
Flow of the Production Card

Production Card
Supplying Process
product
120
Kanban Signal Tool to Trigger Production

Signal (Triangle)
Long changeover times Production in lot size
121
Production by Lot Size

Withdrawal Period 2nd 3rd
1st
4th
Direct Relationship between Changeover times and Inventory Levels
122
Signal (Triangle)
WORK UNIT NAME PART No.
CONTAINER QUANTITY TYPE
PROCESSING TIME FOR 1 LOT
LOT SIZE
ORDER POINT
# of containers to produce
Where the signal

Signal #
is placed in inventory
123
Signal Triangle
When using the Signal Triangle, every part number on the work unit has its own signal
The signal instructs the work unit to produce and is dependent on how inventory is pulled from the work unit
If parts are not withdrawn from the work unit, the work unit will not receive a signal to produce
124
Lot Size Production

Signal Instructs the Work Unit:
When to produce the part
How many to produce at one time
125
Elements Required to Determine the Lot Size
Available Time
Monthly Demand for Each Part Number

Production Time for Each Part Number Average Changeover Time
126
Available Time
Available Time =
(Number of Hours per Shift) (Break Time)
Number of Shifts: 2 Number of Breaks per Shift: 2
Hours per Shift: 8 Minutes per Break: 10
57,600 seconds - 2,400 seconds = 55,200 seconds
127
Demand Calculation
Daily Demand = Monthly Demand # of Days in Demand Period
Days in Month = 20 Part A B C D Total Monthly Demand 4000 pcs 6000 pcs 8000 pcs 12000 pcs 30000 pcs Daily Demand 200 pcs 300 pcs 400 pcs 600 pcs ???? pcs
128
Demand Calculation
Days in Month = 20 Part A B C D Total Monthly Demand 4000 pcs 6000 pcs 8000 pcs 12000 pcs 30000 pcs Daily Demand 200 pcs 300 pcs 400 pcs 600 pcs 1500 pcs
129
Calculating Production Time

Production Time = Cycle Time x Daily Demand
Part A B C D Total
Daily Demand 200 300 400 600 1500
Cycle Time 28.5 28.0 30.5 32.0 30.3
Production Time 5700 8400 12200 19200 ??????
130

Part A B C D Total
Daily Demand 200 300 400 600 1500
Cycle Time 28.5 28.0 30.5 32.0 30.3
Production Time 5700 8400 12200 19200 45500
131
Calculating Average Changeover Time

Part A B C D Total Daily Demand 200 300 400 600 ???? Changeover Time 900 seconds 600 seconds 720 seconds 600 seconds ???? seconds
Total Average C/O Time = Changeover Time = ???? = ??? # of Parts Numbers ?
132

Part A B C D Total Daily Demand 200 300 400 600 1500 Changeover Time 900 seconds 600 seconds 720 seconds 600 seconds 2820 seconds
Total Average C/O Time = Changeover Time = 2820 = 705 # of Parts Numbers 4
133
Lot Size Calculation

Step 1: Determine the Number of Changeovers per Day # of C/O per Day = Available Time - Production Time Average Changeover Time # of C/O per Day = ????? - ????? ??? = ??? C/Os
(# of Parts)
/ /
(# of Available C/Os)
(?)
(???)
= =
(LOT SIZE) ??? Days

134

Step 1: Determine the Number of Changeovers per Day # of C/O per Day = Available Time - Production Time Average Changeover Time # of C/O per Day = 55,200 - 45,500 705 = 13.7 C/Os
(# of Parts)
/ /
(4)
(13.7)
= =
(LOT SIZE) .29 Days

135
Lot Size per Part Number
Part A B C D
Daily Demand 200 300 400 600
Lot Size 0.29 days 0.29 days 0.29 days 0.29 days
# in Lot 58 pcs 87 pcs 116 pcs 174 pcs
136
Container Lot Size

# of Containers in a Lot = Lot Size Qty per Cont. Example: Lot Size for Part A = 58 pcs Container Size = 30 pcs Part A = 58 pcs per lot size = 1.9 containers 30 pcs per container
Round Up to Next Full Container
Part A Lot Size = 2 Containers
137
Order Point
The order point determines how much inventory is needed in the stores to cover customer requirements during the work units peak period of downtime For instance, the order point = 2
The signal is placed on the 2nd to the last container. When the container above the signal on is pulled, exposing the Signal Triangle, the signal goes back to the line to trigger production with the corresponding amount of Production Cards
138
Signal (Triangle)
Pull from Top
Remove Signal Triangle when this container is pulled!!
139
Order Point Calculation

(Daily Demand x Downtime Percentage) = Order Point Quantity per Container Daily Demand: 200pcs Peak Downtime Percentage: 20% Quantity per Container: 30pcs Order Point: 2 (200 x .20) = 1.33 30
Round Up to Next Full Container
140
Order Points
Part Daily Demand A B C D 200 300 400 600 D/T #PCS Pcs/Cont O.P. .20 .20 .20 .20 40 60 80 120 30 30 30 30 ? ? ? ?
141
Order Points
Part Daily Demand A B C D 200 300 400 600 D/T #PCS Pcs/Cont O.P. .20 .20 .20 .20 40 60 80 120 30 30 30 30 2 2 3 4
142
How are the Containers Identified?

A Production Card is placed on a container after it is produced When the container is pulled from the store the Production Card is removed and is put into a collection box, while a Move Card is put on the container in its place When the signal is sent to the work unit for production, the number of Production Cards that are needed to I.D. the containers are also taken
143
1.
Move Card signals that the Customer Work Unit needs parts.
Inventory Stores
2.
The container is picked and the Kanban Card is replaced with the Move Card.
Inventory Stores
3.
The Production Card is put into a collection box to be sent back to the work unit. Parts are taken to the Customer Work Unit.
144
Inventory Stores
# of Production Cards in the System

# of Production Cards = Lot Size + Order Point
=2+2
= 4 Tags The number of cards is the maximum amount of material that will be in the stores
145
Flow Of The Signal ( Triangle)

Customer Pulling
C Now Next
A D
ABCD
Signal Board B
Order
Point
Collection Box
Roll Cut Stores
Roll Cut Work Unit

146
Lot Box Production
An Alternative Approach for Increased Visual Management
147
Lot Box Production Flow

Production Card
Lot Box Supplying Process

product
148
The Lot Box

Container # 5 6
Part A B C D
10
Production Cards
Order Point
Zero Inventory
149
Work Unit Kanban Post

1st Shift
6 0 0
6 0 6
6 1 2
6 1 8
6 2 4
6 3 0
6 3 6
6 4 2
6 4 8
6 5 4
7 0 0
7 0 6
7 1 2
7 1 8
7 2 4
7 3 0
7 3 6
7 4 2
7 4 8
7 5 4
8 0 0
Line 100
Part D
C/O Card
Part A
C/O Card
150
A
Daily Dem an d
B
L ot S iz e
C
Cycle T im e
D
C/O
E
L ot T im e
F
T otal Ru n
I Calculations E=(BXC) F=(D+E) H=(GXC)/60 I=D/60
Con tain er S iz e M in . / Con tain er C.O . T im e ( m in .)
Part # 1 A B C D
Container No. 2 3 4 5
C/O
Total
Example for Part # C

1 15.25
6 0 0
2 30.5
6 0 6 6 1 2 6 1 8
3 45.75
6 2 4 6 3 0
4 61
6 3 6 6 4 2 6 4 8
5 X
6 5 4 7 0 0
6 X
7 0 6 7 1 2 7 1 8
C/O 12
7 2 4 7 3 0
TOTAL 73
7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
1st Shift
Line 100
A: I
I -
B: I C: I D: I
I I - I
- I - - I - I - - I -
- I
- I - 152
Lot Box Production
Visual Aid 2 (An Alternative Approach)
153
Objective
To visually demonstrate the flow of Cards based on lot size production using the Lot Box as a tool for instruction to produce.
154
Visual Aid Requirements

1 Lot Box 1 Kanban Post 1 Parts Withdrawal Timing Sheet 4 (Part A) Production Cards 5 (Part B) Production Cards 7 (Part C) Production Cards
10 (Part D) Production Cards

17 Changeover Cards
155
Visual Aid Layout

Lot Box
Part A B C D 1 2 3 4 Container # 5 6 7 8
10
Kanban Post
1st Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
Line 100
156
Visual Aid Layout Inventory Status
Part A 1 Container 1 Container
Part B 1 Container 1 Container 1 Container 1 Container
Part C 1 Container 1 Container 1 Container 1 Container 1 Container
Part D 1 Container 1 Container 1 Container 1 Container 1 Container

157
Part Withdrawal Timing Part A 8:10 am 10:38 am 1:36 pm 5:54 pm 8:22 pm 11:10 pm Part B 7:32 am 9:14 am 10:46 am 12:48 pm 2:30 pm 6:02 pm 7:44 pm 9:16 pm 11:18 pm 1:00 am Part C 7:09 am 8:18 am 9:37 am 10:46 am 12:25 pm 1:44 pm 4:53 pm 6:02 pm 7:21 pm 8:30 pm 10:09 pm 11:18 pm 12:37 am Part D 6:28 am 7:14 am 8:00 am 8:56 am 9:42 am 10:28 am 11:44 am 12:30 pm 1:26 pm 2:12 pm 4:58 pm 5:44 pm 6:30 pm 7:26 pm 8:12 pm 8:58 pm 10:14 pm 11:00 pm 11:56 am 12:42 am
158
Board Status - 6:00 am

Lot Box
10
Kanban Post
1st Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
Line 100
159
Board Status 6:00 am

Lot Box
10
Kanban Post
1st Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
Line 100
160
Inventory Status - 6:00 am

Part A 1 Container 1 Container Part B 1 Container 1 Container 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container 1 Container Part D 1 Container 1 Container 1 Container 1 Container 1 Container
161

Lot Box
10
Kanban Post
1st Shift 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 3 0 8 3 6 8 4 2
Line 100
B / T
B / T
162

Lot Box
10
Kanban Post
1st Shift 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6 8 1 2 8 1 8 8 2 4 8 3 0 8 3 6 8 4 2
Line 100
B / T
B / T
163
Part A 1 Container 1 Container 1 Container 1 Container
Part D 1 Container 1 Container 1 Container 1 Container
164

Lot Box
10
Kanban Post
1st Shift 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4 1 0 0 0 1 0 0 6 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0 1 0 3 6 1 0 4 2
Line 100
165

Lot Box
10
Kanban Post
1st Shift 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4 1 0 0 0 1 0 0 6 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0 1 0 3 6 1 0 4 2
Line 100
166
Part A
1 Container 1 Container 1 Container
Part B
Part C
Part D
1 Container 1 Container 1 Container 1 Container 1 Container 1 Container
1 Container
1 Container
167

Lot Box
10
Kanban Post
1st Shift 9 5 4 1 0 0 0 1 0 0 6 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0 1 0 3 6 1 0 4 2 1 0 4 8 1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4
Line 100
L L / / T T
L / T
L L / / T T
168

Lot Box
10
Kanban Post
1st Shift 9 5 4 1 0 0 0 1 0 0 6 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0 1 0 3 6 1 0 4 2 1 0 4 8 1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4
Line 100
L L / / T T
L / T
L / T
L / T
169
Inventory Status 9:54 am

Part A 1 Container 1 Container Part B 1 Container 1 Container Part C 1 Container 1 Container
Part D 1 Container 1 Container
1 Container
1 Container
1 Container
1 Container
1 Container
1 Container
1 Container
1 Container
1 Container
170

Lot Box
10
Kanban Post
1st Shift 1 0 4 8 1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 3 0 1 1 3 6 1 1 4 2 1 1 4 8
1 1 5 4
1 2 0 0
1 2 0 6
1 2 1 2
1 2 1 8
1 2 2 4
1 2 3 0
1 2 3 6
1 2 4 2
1 2 4 8
Line 100
L L / / T T
L / T
L L / / T T
171

Lot Box
10
Kanban Post
1st Shift 1 0 4 8 1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 3 0 1 1 3 6 1 1 4 2 1 1 4 8
1 1 5 4
1 2 0 0
1 2 0 6
1 2 1 2
1 2 1 8
1 2 2 4
1 2 3 0
1 2 3 6
1 2 4 2
1 2 4 8
Line 100
L / T
L L L / / / T T T
L / T
172
Inventory Status 10:48 am

Part A Part B Part C Part D
1 Container
1 Container
1 Container
1 Container
1 Container 1 Container 1 Container 1 Container
1 Container
173
Board Status - 12:02 pm

Lot Box
10
Kanban Post
1st Shift 1 2 0 0 1 2 0 6 1 2 1 2 1 2 1 8 1 2 2 4 1 2 3 0 1 2 3 6 1 2 4 2 1 2 4 8 1 2 5 4 1 0 0 1 0 6 1 1 2 1 1 8 1 2 4 1 3 0 1 3 6 1 4 2 1 5 4 2 0 0 2 0 6
Line 100
B / T
B / T
174

Lot Box
10
Kanban Post
1st Shift 1 2 0 0 1 2 0 6 1 2 1 2 1 2 1 8 1 2 2 4 1 2 3 0 1 2 3 6 1 2 4 2 1 2 4 8 1 2 5 4 1 0 0 1 0 6 1 1 2 1 1 8 1 2 4 1 3 0 1 3 6 1 4 2 1 5 4 2 0 0 2 0 6
Line 100
B / T
B / T
175
Inventory Status - 12:02 pm

Part A Part B Part C Part D
1 Container
1 Container
1 Container
1 Container
176
Board Status 1:58 pm

Lot Box
10
Kanban Post
1st Shift 1 5 4 2 0 0 2 0 6 2 1 2 2 1 8 2 2 4 2 3 0 2 3 6 2 4 2 2 4 8 2 5 4 3 0 0 3 0 6 3 1 2 3 1 8 3 2 4 3 3 0 3 3 6 3 4 2 3 4 8 3 5 4
Line 100
E O S
B / S
B B B B / / / / S S S S
B / S
B B / / S S
B B / / S S
B B B B / / / / S S S S
177

Lot Box
10
Kanban Post
1st Shift 1 5 4 2 0 0 2 0 6 2 1 2 2 1 8 2 2 4 2 3 0 2 3 6 2 4 2 2 4 8 2 5 4 3 0 0 3 0 6 3 1 2 3 1 8 3 2 4 3 3 0 3 3 6 3 4 2 3 4 8 3 5 4
Line 100
E O S
B / S
B B B B / / / / S S S S
B / S
B B / / S S
B B / / S S
B B B B / / / / S S S S
178
Inventory Status 1:58 pm

Part A 1 Container 1 Container 1 Container Part B 1 Container 1 Container 1 Container Part C 1 Container 1 Container 1 Container Part D 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container
179

Lot Box
10
Kanban Post
2nd Shift 4 3 0 4 3 6 4 4 2 4 4 8 4 5 4 5 0 0 5 0 6 5 1 2 5 1 8 5 2 4 5 3 0 5 3 6 5 4 2 5 4 8 5 5 4
6 0 0
6 0 6
6 1 2
6 1 8
6 2 4
6 3 0
Line 100
180

Part A 1 Container 1 Container 1 Container Part B 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container 1 Container Part D 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container
181

Lot Box
10
Kanban Post
2nd Shift 5 0 6 5 1 2 5 1 8 5 2 4 5 3 0 5 3 6 5 4 2 5 4 8 5 5 4 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0
6 3 6
6 4 2
6 4 8
6 5 4
7 0 0
7 0 6
Line 100
B / T
B / T
182

Part A 1 Container 1 Container 1 Container Part B 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container
1 Container
1 Container
1 Container
1 Container
183

Lot Box
10
Kanban Post
2nd Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4
7 3 0
7 3 6
7 4 2
7 4 8
7 5 4
8 0 0
Line 100
B / T
B / T
184

Lot Box
10
Kanban Post
2nd Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4
7 3 0
7 3 6
7 4 2
7 4 8
7 5 4
8 0 0
Line 100
B / T
B / T
185

Part A 1 Container 1 Container Part B 1 Container 1 Container 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container 1 Container Part D 1 Container 1 Container 1 Container 1 Container 1 Container
186

Lot Box
10
Kanban Post
2nd Shift 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6
8 1 2
8 1 8
8 2 4
8 3 0
8 3 6
8 4 2
Line 100
B B / / T T
187

Lot Box
10
Kanban Post
2nd Shift 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0 8 0 6
8 1 2
8 1 8
8 2 4
8 3 0
8 3 6
8 4 2
Line 100
B B / / T T
188
Part A 1 Container 1 Container 1 Container 1 Container
189

Lot Box
10
Kanban Post
2nd Shift 8 3 0 8 3 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4 1 0 0 0 1 0 0 6 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0
Line 100
L / T
L L L / / / T T T
L / T
190

Lot Box
10
Kanban Post
2nd Shift 8 3 0 8 3 6 8 4 2 8 4 8 8 5 4 9 0 0 9 0 6 9 1 2 9 1 8 9 2 4 9 3 0 9 3 6 9 4 2 9 4 8 9 5 4 1 0 0 0 1 0 0 6 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0
Line 100
L / T
L L L / / / T T T
L / T
191
Part A 1 Container 1 Container 1 Container
Part B 1 Container 1 Container
Part C 1 Container 1 Container 1 Container
Part D 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container
To be filled At 8:32.5
192

Lot Box
10
Kanban Post
2nd Shift 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0 1 0 3 6 1 0 4 2 1 0 4 8 1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 3 0 1 1 3 6 1 1 4 2 1 1 4 8 1 1 5 4 1 2 0 0 1 2 0 6 1 2 1 2
Line 100
B / T
B / T
193

Lot Box
10
Kanban Post
2nd Shift 1 0 1 2 1 0 1 8 1 0 2 4 1 0 3 0 1 0 3 6 1 0 4 2 1 0 4 8 1 0 5 4 1 1 0 0 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 3 0 1 1 3 6 1 1 4 2 1 1 4 8 1 1 5 4 1 2 0 0 1 2 0 6 1 2 1 2
Line 100
B / T
B / T
194

Part A 1 Container Part B 1 Container Part C 1 Container
Part D 1 Container
1 Container
1 Container
1 Container
1 Container
1 Container
1 Container 1 Container 1 Container 1 Container 1 Container
195

Lot Box
10
Kanban Post
2nd Shift 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 3 0 1 1 3 6 1 1 4 2 1 1 4 8 1 1 5 4 1 2 0 0 1 2 0 6 1 2 1 2 1 2 1 8 1 2 2 4 1 2 3 0 1 2 3 6 1 2 4 2 1 2 4 8 1 2 5 4 1 0 0 1 0 6
Line 100
B / T
B / T
E O S
B / S
196

Lot Box
10
Kanban Post
2nd Shift 1 1 0 6 1 1 1 2 1 1 1 8 1 1 2 4 1 1 3 0 1 1 3 6 1 1 4 2 1 1 4 8 1 1 5 4 1 2 0 0 1 2 0 6 1 2 1 2 1 2 1 8 1 2 2 4 1 2 3 0 1 2 3 6 1 2 4 2 1 2 4 8 1 2 5 4 1 0 0 1 0 6
Line 100
B / T
B / T
E O S
B / S
197

Part A 1 Container 1 Container 1 Container Part B 1 Container 1 Container 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container
1 Container
1 Container
1 Container
1 Container
198

Lot Box
10
Kanban Post
2nd Shift 1 1 5 4 1 2 0 0 1 2 0 6 1 2 1 2 1 2 1 8 1 2 2 4 1 2 3 0 1 2 3 6 1 2 4 2 1 2 4 8 1 2 5 4 1 0 0 1 0 6 1 1 2 1 1 8 1 2 4 1 3 0 1 3 6 1 4 2 1 4 8 1 5 4
Line 100
E B O / S S
B / S
B B / / S S
B / S
B / S
B / S
B B / / S S
199

Lot Box
10
Kanban Post
2nd Shift 1 1 5 4 1 2 0 0 1 2 0 6 1 2 1 2 1 2 1 8 1 2 2 4 1 2 3 0 1 2 3 6 1 2 4 2 1 2 4 8 1 2 5 4 1 0 0 1 0 6 1 1 2 1 1 8 1 2 4 1 3 0 1 3 6 1 4 2 1 4 8 1 5 4
Line 100
E B O / S S
B / S
B B / / S S
B / S
B / S
B / S
B B / / S S
200

Part A 1 Container 1 Container 1 Container Part B 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container
1 Container
1 Container
1 Container
201
Board Status - 6:00 am Day 2

Lot Box
10
Kanban Post
1st Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
Line 100
202
Inventory Status - 6:00 am Day 2

Part A 1 Container 1 Container 1 Container 1 Container Part B 1 Container 1 Container 1 Container Part C 1 Container 1 Container 1 Container 1 Container Part D 1 Container 1 Container 1 Container 1 Container 1 Container 1 Container
203
Exercise 3 (An Alternative Approach)
204
Calculation Exercise Data Data

Part Monthly Demand Changeover Time A 10,000 720 B 8,000 600 C 9,000 720 D 11,000 600 Cycle Time 22 23 21 22 Container Size 30 30 30 30
205
Available Time
Available Time = Number of hours per Shift - Break Time
Number of Shifts: 2 Number of Breaks Per Shift: 2
Hours Per Shift: 8 Minutes Per Break: 10
Available Time=
206
Available Time
Available Time = Number of hours per Shift - Break Time
Number of Shifts: 2 Number of Breaks Per Shift: 2
Hours Per Shift: 8 Minutes Per Break: 10
Available Time = 55,200
207
Demand Calculation
Days In Month = 20
Part A B C D Total
Monthly Demand 10,000 8,000 9,000 11,000
Daily Demand
208
Demand Calculation
Days In Month = 20
Part A B C D Total
Monthly Demand 10,000 8,000 9,000 11,000
Daily Demand 500 400 450 550
209

Part A B C D Total
Daily Demand
Cycle Time 22 23 21 22
Production Time
210

Part A B C D Total
Daily Demand 500 400 450 550 1,900
Cycle Time 22 23 21 22
Production Time 11,000 9,200 9,450 12,100 41,750
211

Part A B C D Total Daily Demand Changeover Time 720 600 720 600
Average C/O Time = Total Changeover Time = # of Parts Numbers

212
Part A B C D Total
Daily Demand 500 400 450 550 1,900
Changeover Time 720 600 720 600 2,640
Total Average C/O Time = Changeover Time = 2,640 = 660 # of Parts Numbers 4
213

Step 1: Determine The Number of Changeovers per Day # of C/O per day = Available Time - Production Time Average Changeover Time
# Of C/O Per Day =
(# of Parts)
4
/ /
= =
(LOT SIZE)
214

Step 1: Determine The Number of Changeovers per Day # of C/O per day = Available Time - Production Time Average Changeover Time # Of C/O Per Day = 55,200 41,750 = 20.38 660
(# of Parts)
4
/ /
20.38
= =
(LOT SIZE)
.19
215
Lot Size Per Part Number
Part A B C D
Daily Demand
Lot Size
# in Lot
216
Lot Size Per Part Number
Part A B C D
Daily Demand 500 400 450 550
Lot Size .19 .19 .19 .19
# in Lot 95 76 85.5 104.5
217
Container Lot Size

# of Containers in a Lot =
Lot size Qty per Cont.
Example: Lot Size for Part A = Container Size = 30

Part A =
Part A Lot Size =

218
Questions
A
Daily Dem an d
B
L ot S iz e
C
Cycle T im e
D
C/O
E
L ot T im e
F
T otal Ru n
Con tain er S iz e M in . / Con tain er C.O . T im e ( m in .)
Part # 1 A B C D
Container No. 2 3 4 5
C/O
Total
219
Answers
A
Daily Dem an d
B
L ot S iz e
C
Cycle T im e
D
C/O
E
L ot T im e
F
T otal Ru n
G 30.0 30.0 30.0 30.0
Con tain er S iz e M in . / Con tain erC.O . T im e ( m in .)
500 400 450 550
120 90 90 120
22 23 21 22
720 600 720 600
2640 2070 1890 2640
3360 2670 2610 3240
Part # A B C D 1 11.0 11.5 10.5 11.0
Container No. 2 3 4 5 22.0 33.0 44.0 23.0 34.5 21.0 31.5 22.0 33.0 44.0 -
6 -
C/O 12.0 10.0 12.0 10.0
Total 56.0 44.5 43.5 54.0
220
Example
1st Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
Line 100
A: B:
C: D:
221
Example
1st Shift 6 0 0 6 0 6 6 1 2 6 1 8 6 2 4 6 3 0 6 3 6 6 4 2 6 4 8 6 5 4 7 0 0 7 0 6 7 1 2 7 1 8 7 2 4 7 3 0 7 3 6 7 4 2 7 4 8 7 5 4 8 0 0
Line 100
A: B:
I I
I I
- I - I
- I -
C: D:
I I
I I
- I - I
- I
222
Material Movement
(Focus of On-Time Delivery)
223
Internal Material Movement
Move Card
Standard Delivery Route
224
Move Card
The move card tells us: What to move Where to find and take material Standard material quantity
When to move
225
Move Card
SUPPLIER NAME
Kanban Signal No. WORK UNIT NAME
PART No.
QUANTITY
CARD #
226
Flow of Move Card

Move Card
Internal
Raw Material Store Production Work Unit
Needed product
227
Kanban, A new Approach
When Do I Remove the Move Card?

When the first piece is taken, the Move card is removed
Move Card
Partial Card
A partial card can be any color that attracts attention.
There is only one partial card for each component part on a line.
SUPPLIER NAME
Kanban Signal #
WORK UNIT NAME
PART No.
Partial
229
Standard Route of Delivery

Why do we need a standard route of delivery? To eliminate waste To reduce inventory
To guarantee on time delivery
230

Pick Area
Line 1
Line 3
Line 2
231

Pick Area
Line 1
Line 3
Line 2
232
Part No. Part Name Line
CC3330 Converter Assy

# of Members 1
STANDARDIZED WORK CHART MATERIAL HANDLER

Cell Takt Time Delivery Cycle
Date Stops
08/30/99
Daily Customer Demand
Shifts
2
Bottleneck
Manual Time
4440
90
60
20
15
Standard In-Process Stock
920
Raw Material Store
30
90
Orbital Welder
Finished Goods
30
1 30 Manual Weld Bracket
240 30
Linear Weld
3
30
Marking Machine
Rolling Machine
Secure Tig Tack Wrap Tourniquet Machine 6
Press Sizer
90
90
Manual Member Time Walk Time Total Time
4
30 15
5
30 25
30
420
480
900
How Many Withdrawal Cards Are There?

The Number of Withdrawal Cards is Based on: Time of the standard route of material deliveries Usage rate of material by the work unit Quantity per container of material
234
Calculating Number of Move Cards
Delivery Cycle = Time to make standard delivery cycle in hours

Quantity per Hour = # of parts produced by the work unit in 1hour based on target cycle time # of Move Cards = Delivery Cycle x Qty per Hr x 2 Quantity per Container
One set of cards in Process One set of cards in Que
235
Number of Move Cards in the System

# of Move Cards = Delivery Cycle x Qty per Hr x 2 Qty per Container
# of Move Cards = 0.5 hour x 100 parts/hour x 2 25 Parts per Container # of Move Cards = 4
236
How Many Withdrawal Cards are in the System for an Outside Supplier ?
Need to know : Agreed upon delivery cycle Daily demand Quantity per container Safety Stock
237
Kanban Cycle
Agreed upon delivery cycle
This is usually stated as 3 numbers

A:B:C
In A days
There are B trucks Parts are returned C shipments after Cards are sent back to the supplier
238
Delivery Cycle
Delivery Cycle 1:2:3
in 1 day : there are 2 deliveries : and parts arrive 3 shipments after cards are sent to supplier
Monday
Truck 1 2 Truck 2 1 3
Tuesday
Wednesday
Thursday
Friday
SUPPLIER
239
How Many Withdrawal Cards are in the System for an Outside Supplier?
# of Supplier = Daily Demand x A x (C+1) + D Qty per Cont. B
x
Daily Demand Qty per Cont.
A: # of days
B: # of trucks
C: when the Cards return D: Safety Stock Safety Stock covers problems with delivery due to supplier
240
Daily Demand = 1500pcs Qty/Cont. = 30pcs per container Delivery Cycle = 1:2:3 D = .5 Days
A: # of days B: # of trucks C: when the Cards return D: Safety Stock
# of Supplier = Daily Demand x A x (C+1) + D x Daily Demand Qty per Cont. B Qty per Cont.
= 1500pcs
1 x (3+1) + 30pcs per Cont. 2

x
.5 x 1500
30
= 50 Containers x 2 + 25 = 125 Cards

241
Supplier Card Flow
Truck 25 cards
Supplier processing 25 cards
By using 25 cards
Safety Stock Truck 25 cards 25 cards
242
Supplier Card Calculation
Exercise 4 (Card Requirements)
243
Daily Demand = 2000 pieces Qty/Cont. = 50 pieces / container Delivery Cycle =A:B:C 1:6:3 D = .25 days
# of Supplier = Daily Demand x A x (C+1) + D x Daily Demand Qty/Cont. B Qty/Cont
# of Supplier =
244
Daily Demand = 2000 pieces Qty/Cont. = 50 pieces / container Delivery Cycle =A:B:C
1:6:3
D = .25 days
# of Supplier = Daily Demand x A x (C+1) + D x Daily Demand Qty/Cont. B Qty/Cont # of Supplier = 2000 * 1 * (3+1) + .25 * 2000 50 6 50 # of Supplier = (40 containers * .67) + 10 # of Supplier = 36.8 cards = 37 cards (Round up)
245
Kanban System Summary

Key to Successful Information Flow
Customer Internal Supplier
Opportunities for Improvement

Inventory reduction Lead-time reduction Greater flexibility Better visual management
246
No Pain, No Gain
The truth about a Kanban System
Easy to use and follow Difficult to implement
Keys to success in the Kanban System

Training Trial and error Team problem solving Perseverance
247
Initial Start-Up
Start at the beginning of the chain and work your way downstream
Customer loop Internal pull Transition to the supplier
Anticipate problems, they will happen!!!
248
Think Long-Term
Learn the basics first
Understand the root cause of problems Take action after the root cause is clear
Initial inventory goes up

Plan out your strategy Communicate your plans to upper management
249
Be Prepared to Deliver
250
Get Serious !!!
251

Kanban

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KB001 Kanban A New Approach

Kanban A New Approach (Tool for Information Flow)

KB001 Kanban A New Approach

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When to move it!

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Withdrawal Kanban Signal

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Three Types of Withdrawal Kanban Signals

Move Kanban Signal

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Customer Kanban Signal Information

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Customer Kanban Signal

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Flow of Move Kanban Signal

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Work Unit Address

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Part Name Store Address Work Unit Address

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Flow of Supplier Kanban Signal

Internal Raw Material Store

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Flow of Withdrawal Kanban Signals

Internal External Supplier

Internal Production Work needed Unit product

Plant Finished Goods Store External Customer

Raw Materials Store

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Production Kanban Signal

KB001 Kanban A New Approach