The Kanban Course. Facilitator s Guide

Transcription

1 The Kanban Course Facilitator s Guide learn how to calculate the number of Production and Withdrawal Kanban needed with the 2 Card Kanban System. A step by step guide to presenting Gemba Academy s 5S course to lean learners in all positions. This guide includes key points, discussion items, quiz questions and answers, and helpful tips. Using Gemba Academy s online learning content, any facilitator can instruct teams of people about the proper use of kanban.

2 Preparation and Lesson Plan Use this page to prepare for each training session. Resources Gemba Academy videos Online quizzes Prepare for a Successful Training Session Watch videos and complete quizzes on your own at least one day before the training session. Read this guide thoroughly and become familiar with the course content before presenting to others. Prepare a suitable training room for your participants. Prepare a computer with internet access and a projector or large screen. Test all equipment before the training session. Have your Gemba Academy username and password ready. U: P: Choose your quiz style. The most popular option is to use the online interactive quiz, answering questions as a group with open discussion. Another option is to print the PDF version and have participants complete the quizzes individually. Training Session Outline Step 1: Introduce the session topic and content to the participants. Step 2: Play a video. Step 3: Lead a group discussion using this guide. Review key points, ask prepared questions and have participants fill in the blanks in their workbooks. Step 4: Take the quiz and review responses. Step 5: Apply what has been learned in your workplace. Choose Your Quiz Style When questions come up, encourage other participants to answer. Responding to questions with What does the team think? goes a long way to build engagement. Helpful Tip 1

3 Step 1: Session Overview Introduce the training topic. This module explains the parameters used to calculate the number of kanban needed, as well as how to use the kanban calculator we provide along with the module. Explain what to expect during this session. In this session we will: Watch (5:07) Discuss what we learned from the video using the workbook Review the content with a quiz and talk about the results. Before you begin Ask your participants what they think the amount of kanban in a system depends on. Is it tied to the amount of inventory in the process, or is there another factor? Step 2: Play Step 3: Review Key Points Kanban System Variables Overview Done correctly, the kanban calculation shows how many parts are needed in the system, the number of production and withdrawal cards in the loop, and when replenishment will happen, since kanban cards trigger all make & move production activities. Four key variables: 1. Average Daily Demand (AD) 2. Replenishment Lead Time (RT) 3. Safety Factor (SF) 4. Container Quantity (CQ) Average Daily Demand AD assumes productions smoothing (heijunka) is in place with averaged mix and volumes across a set period of time. AD may allow up to 10% buffer stock based on the variation in your demand figures. If your variation is much larger than that, you ll need to focus on smoothing it before attempting to implement a kanban system. Replenishment Time RT is the time lapse from the order signal to the replenishment of material. RT is not the same as production lead time. RT may include things such as kanban collection and delivery time, picking time from the finished goods supermarket, processing time, waiting time, transport time between plants, 2

4 time to receive and process parts, conveyance time within plants, and the time to place parts at point of use. It can also be thought of as the total elapsed time between points A & B in the kanban loop. Safety Factor SF helps us take into account factors such as downtime, quality losses, transportation delays, weather delays, etc. SF is expressed as a percentage of the total demand. Our goal should be to reduce all issues, but when first starting with kanban, err on the conservative side and begin with more than enough to cover material outages. SF may be arbitrary at first if good data is unavailable, but our accuracy must continuously improve. Kanban Quantity Calculation The equation for calculating kanban quantities is: Step 4: Quiz 1. Calculating the number of cards to be used in a 2-Card Kanban System determines what? Please select all that apply. The optimal crew size When replenishment will happen How many parts are needed in the system How many cards are needed in the system 2. The Average Daily Demand used in the 2-Card Kanban quantity calculation assumes production smoothing. True False 3

5 3. The Replenishment Time (RT) used in the 2-Card Kanban quantity calculation normally equals the Production Lead Time. True False 4. Assuming an Average Daily Demand of 65 units, a Replenishment Lead Time of 5 days, a Safety Factor of 5%, and a Container Quantity of 15, how many kanban cards are required? Feel free to use the free calculator provided in the resources column or on the DVD Assuming an Average Daily Demand of 2000 units, a Replenishment Lead Time of 10 days, a Safety Factor of 5%, and a Container Quantity of 1000, how many kanban cards are required? Feel free to use the free calculator provided in the resources column or on the DVD Step 5: Reflection Give your participants minutes to fill out the reflection questions at the end of their workbooks. When they ve finished, have a short discussion with them. Do you think your company would benefit from using this system? Now that you know how to calculate the amount of kanban necessary in a 2-card system, can you calculate how many kanban your process would need? Spend 5-10 minutes discussing. 4