The Kanban Course. Workbook. The 6 Kanban Prerequisites In order to succeed with Kanban, there are 6 prerequisites that must be in place.

Size: px

Start display at page:

Download "The Kanban Course. Workbook. The 6 Kanban Prerequisites In order to succeed with Kanban, there are 6 prerequisites that must be in place."

Myles Brooks
5 years ago
Views:

The Kanban Course Workbook In order to succeed with Kanban, there are 6 prerequisites that must be in place. A workbook intended to accompany the Facilitator s Guides for this course.

1 The Kanban Course Workbook In order to succeed with Kanban, there are 6 prerequisites that must be in place. 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 Prerequisite 1: Heijunka To succeed with kanban, must be in place. Without it, the kanban system will have excess resources, excess inventory levels, and the need to constantly adjust kanban. There must not be large demand swings Inventory levels will constantly need to be adjusted. If the supplier does not have heijunka in place, kanban can cause an in inventory in order to support downstream pull. Kanban can only function if you know what you will produce tomorrow. Prerequisite 2: Small Lot Production Without small lot sizes, the system will have more kanban cards, off-line storage areas for unnecessary parts, and will be less responsive to downstream pull. One of the most important aspects of producing in small lots is performing in changeovers. If the changeovers are long, there may be a loss in production capacity as changeovers become more frequent. Changeover times will also limit the reduction of batch sizes, which limits flexibility and forces increases in buffer inventories, which leads to longer lead-times. Prerequisite 3: Defect-Free Delivery Without defect-free delivery, there will be a mismatch between the information and the materials, shortages when defects are found, and just-in-case inventory. In order to sustain this, there has to be a culture focused on, with systems that allow managers, supervisors, and workers to prevent, detect, and rapidly take root cause corrective action. In addition, the three don ts of Built-In-Quality must be in place: don t make, accept, or ship poor quality. 1

3 Prerequisite 4: Attach Kanban to Containers Without kanban attached to containers, there will be a mismatch between the information on the card and the actual materials, as well as loss of the visual control function of kanban. Prerequisite 5: 5S Discipline If you can t sustain a high level of 5S, don t use kanban. Without 5S discipline, the kanban system will have shortages, delays due to searching, and excess materials. 5S is a fundamental characteristic of Lean, and has many things in common with kanban. Keeping items out of the workplace, having set locations for items, and maintaining standards, are all necessary to avoid losing things. Prerequisite 6: Use Kanban to Expose and Solve Problems Without exposing and solving problems, the system will have inventory than before, chronic problems that make people want to increase buffers, and a disconnection with the continuous improvement culture. We must use kanban as a tool for process improvement, not to hide problems with inventory. 2

Quiz 1. Another way to describe the concept of heijunka: MRP Scheduling Push Production Max Planning Level Loading 2. Quick Changeover is crucial to producing in small lot sizes. 3.

4 Quiz 1. Another way to describe the concept of heijunka: MRP Scheduling Push Production Max Planning Level Loading 2. Quick Changeover is crucial to producing in small lot sizes. 3. The Three Don ts of Built-In-Quality consist of (choose 3): Don t make poor quality Don t accept poor quality Don t ship poor quality Don t talk about poor quality 4. Without 5S discipline, the kanban system will likely have shortages due to misplaced materials. 5. Using kanban is an excellent way to hide quality problems. 3

5 Review How many kanban prerequisites have you and your company implemented already? Which ones are already in place? 4

The Kanban Course. Workbook

The Kanban Course. Workbook 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