The Kanban Course. Facilitator s Guide

Transcription

1 The Kanban Course Facilitator s Guide 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 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 what a kanban and kanban system are, the different functions of kanban, and different types of kanban. Explain what to expect during this session. In this session we will: Watch (7:11) 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 if they have heard the term kanban before. If so, can they define it? Have they ever worked with kanban before? Step 2: Play Step 3: Review Key Points What is a Kanban? Kanban literally means sign board or sign 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 nervous 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 Taiichi Ohno 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 Just-In-Time 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 overproduction and excess inventory, 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. 2

4 Different Functions of Kanban Kanban sets limits, and acts like a type of currency. It s exchanged for items like money is used to buy parts or materials; no kanban, no parts. 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 abnormalities visible, since no material can be without a kanban and vice versa. Types of Kanban 2-Card Kanban: uses production and withdrawal kanban to signal when product is needed to fulfill a customer request. 1-Card Kanban: may not actually use a card, and could be any kind of signal that conveys information. 2-Bin Kanban: standardized bins or containers fulfill the role of the kanban card. Step 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 3

5 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 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 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. Now that you understand what kanban do and the different ways they can be used, do you think kanban can help your organization? How specifically could it help? Spend 5-10 minutes discussing. 4