The Kanban Course. Workbook

Transcription

1 The Kanban Course Workbook In this module you'll learn what kanban are and how they can be used to control the production and movement within any facility. You'll also learn what many of the most common kanban systems are including the simple, but powerful, 2-bin kanban system. A workbook intended to accompany the Facilitator s Guides for this course. This guide includes the Key Points from the video, discussion items, quiz questions, and helpful tips. Using Gemba Academy s online learning content, any participant can use this workbook to facilitate learning in all courses. July 2017

2 Review What is a Kanban? Kanban literally means or in Japanese. In the context of production control, it refers to visual cues that authorize the production or movement of items. Kanban systems are sometimes called the system of a lean production system. Just like our brains send signals to our body, kanban systems give control instructions to every work area. Kanban connects material flow with information flow by attaching kanban cards to the actual goods. It was developed by of Toyota to stop overproduction in his machine shop, which was creating large inventory and costing a lot of money. He was inspired by the American supermarkets product replenishment system, where shelves were restocked only after products were consumed. What Does a Kanban Do? Kanban is a tool of the process. We use the image of a chain lying on the ground to explain the role kanban play: if we try to push the chain, it just clumps together on the floor. if we pull the chain, it becomes taut. Similarly, if we try to push materials through a process, we create and, while if we pull materials from upstream, all of our processes have just the right amount of inventory when they need it Kanban systems aren t perfect; they can be full of wastes such as excessive handling, inventory, and processing. Our goal is not to implement a kanban system, but to implement true one-piece flow. Different Functions of Kanban Kanban sets limits, and acts like a type of. It s exchanged for items like money is used to buy parts or materials; no kanban, no parts. 1

3 When a kanban system functions correctly, nothing is ever made or moved without a kanban signal of some kind; enables companies to limit overproduction. Kanban physically links material and information flow through a card or bar code scan. Kanban also makes visible, since no material can be without a kanban and vice versa. 2

4 Quiz 1. Kanban is a Japanese word that literally means signboard or sign. True False 2. The Kanban system was invented by of the Toyota Motor Corporation. Shigeo Shingo Sakichi Toyoda Yu Darvish Taiichi Ohno 3. Implementing an amazing Kanban System should be the ultimate goal of any Lean-thinking organization. True False 4. What are the functions of Kanban? Please select all that apply. Makes abnormalities visible Sets limits and helps control inventory Links material & information flow Replaces material handlers 3

5 5. A mailbox flag as shown in the image below is an example of what kind of Kanban system? 2-Card Kanban System 2-Bin Kanban System 1-Card Kanban System 4

6 Reflection Do you think kanban could help your organization? If so, how specifically would it help? What kind of kanban system would benefit your organization the most? 5