The Kanban Course. Workbook

Transcription

1 The Kanban Course Workbook Batch Production and Signal Kanban Contains the modules Kanban in Batch Production and Calculating Signal Kanban Quantities 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: Kanban in Batch Production What is a Signal Kanban? Also called a kanban, a signal kanban is used when set-up time is too to maintain single-piece or small-lot production. They are usually yellow and triangular. In a Signal Kanban System, a normal kanban authorizes the preparation of raw materials for the order, while a signal kanban authorizes production of the order. The Signal kanban only works for fixed- or -frequency orders. It s also not the ideal Lean situation, since our focus should be on attacking the long changeovers and working to achieve true one-piece flow. The information on the card is similar to the Production and Withdrawal kanban, but with an additional piece of information: the (describes where the Signal card is to be placed). Review: Calculating Signal Kanban Quantities Signal Kanban System Variables There are six main variables used to calculate the amount of Signal kanban cards: 1. (MD) 2. (CO/M) 3. (AD) 4. (RT) 5. (SF) 6. (CQ) Using this information, we can calculate two things: how many containers we need, and where we place the Signal kanban card. 1

3 The formula for the container quantity is: While this is good information to have, we need to know more in order to make this type of Signal Kanban System work. Specifically, we need to know where to place the Signal kanban card. The formula for placing the card is: 2

4 Quiz 1. A Signal Kanban System is normally used when changeovers are fast and efficient allowing for small lot production. True False 2. When using a Signal Kanban System, a normal authorizes the preparation of the raw materials for that particular order. Triangle kanban Production kanban Withdrawal kanban 3. Within a Signal Kanban System, the triangular Signal kanban authorizes the production of the order. True False 4. Assuming an Average Daily Demand of 75 units, a Monthly Demand of 650 units, 3 Changeovers per Month, a 5% Safety Factor, and a Container Quantity of 50 pieces, how many containers are needed for a Signal Kanban system to operate correctly? Please use the Kanban calculator in the resources column or on the DVD if you need assistance

5 5. Assuming an Average Daily Demand of 75 units, a Replenishment Lead Time of 2 days, a Monthly Demand of 650 units, 3 Changeovers per Month, a 5% Safety Factor, and a Container Quantity of 50 pieces, which position should the Signal Kanban card be placed in for a Signal Kanban System to operate correctly? Please use the Kanban calculator in the resources column or on the DVD if you need assistance

6 Reflection Now that you know what kanban looks like when applied to batch production, do you think this method would benefit your company better? 5