6Sigma六西格瑪精益生產(chǎn)持續(xù)改善分析管理常用工具資料 The_Lean_Enterprise_16_KT_Kanban_Types__22_pgs(看板舉例)

1、The Lean EnterpriseLean FoundationsContinuous Improvement TrainingKanban Types and Operating SystemsKanbanWhat is Kanban?Kan = cardban = signal Card system that controls production & inventory Visual pull system vs. a “black box” push system (MRP)Categories of KanbanInstructionWithdrawalKanbanProduc

2、tion Kanban (non lot production)Triangle Kanban (for lot production)Interprocess KanbanSupplier KanbanTypes of Kanbans & SystemsWhat did a Milk Man do?What did a Bread Man do?Milkman vs. BreadmanReal Life Kanban MilkmanReplenish What Was Consumed.Take Empties Back To FactoryReplenish EmptiesDeliver

3、Only Whats Needed Delivery Milk To HouseConstant Time Breadman Replenishment Replenishment SignalsEmpty Rack Inventoried DailyKanban Card Attached At Reorder PointMRP ReportReplenishment OptionsConstant Quantity or Constant TimeFlow through RackMaterial WarehouseWithdrawal Kanban Rack At Preceding P

4、rocessOutside StoresProduction Ordering ReplenishmentSupplier ReplenishmentPoint Of UseTransmitted Signal (Filled From Finished Goods)Maturity PathStockroomPick List/ MRPKittingCentralized BreadmanP.O.U. Two Bin Warehouse Two Bin Line SideIntegrated SupplyInventory Turn GoalsOne To TwoOnce A MonthTw

5、ice A MonthOnce A Week Replenishment SignalsEmpty BinKanban Card Attached To BinVisual Lines On FloorMRP ReportReplenishment OptionsConstant Quantity Or Constant TimeMaterial WarehouseStockroomSupplier Vendor Managed InventoryPoint Of Use At Line or StockroomTransmitted Signal EDIProduction Ordering

6、 ReplenishmentSupplier ReplenishmentTWO-BIN System The Conveyance is the designated path or standard work that a water spider (material handler) takes to replenish the shelves.Conveyance or Milk Run Route:Pitch: Refers to the time relating to the cycle the “water spider” has to replenish the stock.

7、Pitch is a lean concept and is calculated by multiplying cycle time by pack quantity (the number of products per container transferred to finished goods from the work cell). DefinitionsXXXXXXFlow of workFlow of informationSimple Common KanbanKanban SquaresRack A1234ABCPart 1232Battery ClipLocation A

8、-1-A5Kanban Shelving & Labeling SchemesWeld KanbanBread Man1 Week supplyMilk Man2 days supplyBased on current Mix1 day to paintSteps:Final assy pulls from paint kanban.Paint pulls from Weld kanbanWelder replenishes weld empties, pulls from S/M Kanban Paint replenishes paint kanban daily and puts fin

9、ished units back in Paint KanbanSheet metal replenishes S/M Kanban once a weekSheet Metal KanbanWeldFinal AssySheet MetalPaintKanban No CardsSupplier Kanban With CardsLean Materials Strategy Will Maximize Inventory Turns Through Supplier Managed InventoriesMaterial SupermarketSIPLACE 80SSMT Machines

10、Withdrawal Kanban PostMaterialWithdrawal Kanban CardSupplier delivers Material with Kanban cards from yesterday attached and picks up todays Kanban cardsMaterial Handler (Water Spider) delivers material to supermarketTriangle KanbanEstablished for internal lot-processing or batch worksitesFor proces

11、ses that have lengthy set-up timesProduction time is at a faster pace than that required in the following processThis type of Kanban has a signaling device built in to prepare for change overVisual ManagementKanban used for batchesMold PartDescriptionLocationDateLot SizeTrigger PointTool #PressPart

12、DescriptionPart NumberLocation parts will be consumed (customer)Area defining lot size and time allotted for runArea defines when product needs to be rescheduled for productionDefines which equipment product is dedicated to run onDate is hand written by consuming area when pulledWhat tool is used to

13、 produce this productTriangle Grid DefinitionWeld Cell #1AssemblyCellWeld Cell #2Triangle Kanbans at WorkTook 12 years to flow down kanban within ToyotaIt then took:8 years to have 60% of first tier suppliers on kanban20 years to get 98% of first tier suppliers on kanbanOnly approximately 50% of Toy

14、ota suppliers are using kanban systems internally todayToyota Kanban TimeframeKeep it simpleDevelop strategy in phases toward P.O.U.Utilize stockroom and warehouse on floorThen Eliminate stockroomThen Eliminate warehouseHave supplier continue to play larger roleMake it very visual. Should not have t

15、o count:Label shelves and boxesUse water levelsTaped /sealed boxesColor codes, Bar CodesEgg carton approach, mistake proof systemContinue to reduce quantity and increase replenishment frequency. Kanbans are inventory (evil) and need to be constantly minimized or eliminatedAs you move from Kanbans to Job Order (MTO) replenis