Pull (Kanban) Production

Pull (Kanban) Production

What is pull production

Product is produced only when the next
operations needs it. Ideally, dont build
until the customer has placed an order.
If one piece flow does not exist, a material
replenishment system is required.





Also known as Supermarket Production

A Japanese word, means Visual Board





Apply Kanban as a special tool for
implementing pull production, so it is
also names as Kanban Production.



Kan

Visual

Ban

Board
Pull (Kanban) Production
What is Kanban
Pull (Kanban) Production
Two Types of Pull Production (1/2)

Make To Store
Production Lines

Warehouse

Preceding Station
(Process)
Following Station
(Process)
Following Station
(Process)
Preceding Station
(Process)
Preceding production process keep a minimum inventory of
finished parts, and fill-up for those parts withdrawn by following
process.


Pull (Kanban) Production
Two Types of Pull Production (2/2)

Make To Order
Production Lines

Customer

Place order
Shipping
(Movable Warehouse)

Production take place after order are received, rather than
before
Zero F/G Inventory in warehouse
Pull (Kanban) Production
Push Production V.S. Pull Production
(1/2)
Customer

Push Production
Supplier

Material
Warehouse

Warehouse
F/G

Machining
Line



Assembly Line

Purchasing
Order

Material
Receiving
Plan

Machining
Plan

Assembly
Plan

Production Control

Pull (Kanban) Production
Push Production V.S. Pull Production
(2/2)
Pull Production
Supplier

Material
Warehouse

Machining
Line



Assembly Line

Assembly
Plan

Production Control

Customer

The Kanban serves as to

1.) Provide instruction for
production and withdraw

2.) Control the level of inventory

3.) Prevent production shut down
from materials shortage

4.) Prevent from over - production

5.) Detect irregular processing speeds

6.) Simplify the workload for materials
management
Pull (Kanban) Production
The Function of Kanban














Pull (Kanban) Production
Two Basic Types of Kanban

Production Kanban
This Kanban is used to
order the start of
production at each
production station.

Withdraw Kanban
This Kanban indicates
the timing and quantity
for pick up a new
supply of parts from a
preceding process to
delivery to following
process.

Pull (Kanban) Production
Basic Operation Procedure for
Kanban
Start Production

Finial Assembly
Line
Withdraw
Kanban

Withdraw
Kanban

Production
Kanban

Parts
Machining
Cell
Production Kanban + Parts

Withdraw Kanban + Parts

1) Only allow the following station to
go to preceding station to withdraw
the parts by instruction of Withdraw
Kanban

2) The preceding station only can
produce the quantity by the
instruction of Production Kanban
to replenish those quantity which
had been withdrawn by following
station


Pull (Kanban) Production
The Operation Rule of Kanban (1/2)












Pull (Kanban) Production
The Operation Rule of Kanban (2/2)

3) Without Kanben, can not
producewithdraw the parts

4) All parts should attach with a
Kanban

5) All parts should be 100% good

6) Try to reduce the number of
Kanban for reducing the
inventory level














One Piece Flow Production


Leveling (Heijunka) Production




Standard Work

Pull (Kanban) Production
Premises of implementing Kanban
Production
Quick Changeover