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