Kanban

A kanban (term Japanese meaning “card” or “label”) is a simple hard-bound card which one fixes on the vats or the containers of parts in a line of assembly or a storage section.

This method, installation at the end of the Years 1950 in the factories Toyota, is an information system which functions between two work stations and limit the production of the station upstream to the exact needs for the station downstream. This method is especially adapted to the companies having a repetitive and relatively regular production.

The number of kanban in circulation must be limited to avoid the constitution of too important work-in-progress. The method kanban however does not exempt to establish forecasts of sale and an in the medium term detailed program of production. It is indeed a technique of short-term production control and it can be integrated perfectly in a management of the type MRP.

The system Kanban functions between the stations of downstream production and upstream:

  • the operator downstream starts a container. It then releases the kanban of handling fixed on the container and lays out it in a box,
  • the warehouseman collects the kanban handling and goes to the station upstream,
  • At the station upstream, it removes the kanban production of the full container, the met in another box and substitutes the kanban to him handling,
  • It brings back the container full with the kanban with handling to the station downstream,
  • When the operator of the station upstream filled a container, it looks at the box of kanban of production. If there is a kanban , it removes it, fixes it at a container empties and takes again the production. If there is no kanban , that wants to say that the work-in-progress are sufficient and it waits.
The Japanese engineer Taiichi Ōno or Taiichi Ohno is generally regarded as the inventor of the method kanban .

Rules of establishment of the Kanban system

Regulate 1: For a reference of article given, a station of manufacture produces parts by batches of reduced size, and of which the quantity is always fixed. This batch of parts is placed in a container, on which one fixes the kanban.
  • as soon as the first part of a container is consumed by the station downstream, the kanban which was fixed on this one is transferred on planning from the station upstream.

Regulate 2: The consumption of parts made by the station downstream must be carried out by multiple entireties of the size of a batch (e.g.: 5 containers per day).

  • Any consumption without Kanban must be prohibited
  • Any consumption larger than that written on Kanban must be prohibited
  • Kanban must be physically attached to a container.

Regulate 3: The station upstream must produce only the quantity of articles necessary to the consumption of the station downstream for one period of time given (the day for example). A thorough study must be realized to determine this consumption, and the quantity of kanban to be put in circulation which results from it.

  • Any production exceeding the number of Kanban must be proscribed
  • If several parts are to be produced on a machine, one proceeds by order of that which was delivered in first

Regulate 4: Manufacture by Kanban supposes a quality zero defect.

Regulate 5: One must minimize the number of Kanbans in order to reduce the number of work-in-progress

Regulate 6: Kanbans must be able to adapt to light fluctuations of request

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