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Delivery Kanban Principles Foundation of a Pull System Marek Piatkowski – July 2012

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Introduction - Marek Piatkowski

Professional Background

Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario

from 1987-1994

TPS/Lean Transformation Consulting - since 1994

Professional Affiliations

TWI Network – John Shook, Founder

Lean Enterprise Institute (LEI) – Jim Womack

Lean Enterprise Academy (LEA) – Daniel Jones

LEI Poland – Tomasz Koch, President

Lean Transformation Solutions, Toronto, Canada

www.TWI-Network.com

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What is Pull System?

Pull

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Mr. Ohno's Idea

Food Mart

Supermarket

Warehouse

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Food Mart

Supermarket

SignStockroom

The Supermarket Model

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The Supermarket Suppliers

Food Mart

Supermarket

Warehouse

Supplier Supplier

Stockroom

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Supermarket

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Pull System

In a traditional operation Scheduling department generates

Information by issuing schedules to all departments to deliver or

move material.

Toyota reversed that process. At Toyota every material movement

generates an Information Signal (Kanban).

When parts are “pulled” from the Supermarket, a signal (Kanban) is

sent to the supplying process to deliver more.

Schedule is issued only to the Pacemaker process.

This is called a Pull System.

9 z

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Creating Kanban based Pull

Kanban card

How to send demand to the Supermarket to

create Pull?

z

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Kanban means Visual Signal

Material Delivery - Kanban Card

A visual signal to replenish materials consumed in a lean process. Signal = Card or Label

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Types of Kanban - Signal

Card Container

Light Empty space Electronic

Ball

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Kanban is a Signal

It could be an empty container

Or it could be a card – “Shopping list”

31Marek Piatkowski - F.S.P. Consulting Inc.

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Delivery Kanban Card

Part Description

Warehouse Location Delivery Location

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Examples of Kanban Cards

FIAMM Technologies - Kanban Loop - Line to F/Gs Storage

Part Number Warehouse Storage Location

YF1T-13A803-AC B5Part Description Container Type

YF1T-13A803-AC Ford AM80S Full Size Black Returnable

Production Line # of Parts per container

Line 5 390Special Instructions # of Boxes per Skid

n/a

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Container as a Kanban signal

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Delivery Kanban – Purpose

The only authority to move or deliver material

Represents a standard pack of parts.

No signal - no delivery

Used to control inventory levels inside the warehouse or the facory

It also serves as a container identification

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Kanban System

Kanban is a practical tool of Just-in-Time operation for controlling

movement and delivery of inventory.

Kanban signals to deliver necessary parts, in necessary quantities, at

the necessary time, in the most economical manner.

What is needed

When it is needed

In the needed amount

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Advantages of a Kanban System We control our inventory through the use of Kanbans

We can easily tell what parts we have and what parts we need – we do

not waste time looking for parts

The Pull System should:

Eliminate part shortages

Tell us to build only what the Customer needs

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Lean Transformation SolutionsThis presentation is an intellectual property of F.S.P. Consulting Inc.

No parts of this presentation can be copied or reproducedwithout a written permission from:

Marek Piatkowski F.S.P. Consulting Inc.

iPhone: 416-235-2631Cell: 248-207-0416

Marek.Piatkowski@rogers.comwww.TWI-Network.com