The Kan Ban Game. 2 © The Delos Partnership 2003 To understand how Kanbans Aid the transition from...

The Kan Ban The Kan Ban GameGame

2 © The Delos Partnership 2003

To understand how Kanbans

•Aid the transition from a Push to a Pull System

•Facilitate Continuous Improvement

To understand how Kanbans

•Aid the transition from a Push to a Pull System

•Facilitate Continuous Improvement

The Kanban GameThe Kanban Game

Aim of the game


To Maximise Customer Service

To Minimise Inventory (Finished Goods/WIP/Raw Mats)

To Maximise Customer Service

To Minimise Inventory (Finished Goods/WIP/Raw Mats)

Objectives of the Game



Supply two products (Red,Blue)

Supply two products (Red,Blue)

The Task

Raw Mat Make SquareTape Edges Staple Hole Punch Sticker Finished Goods

Dispense Garnulate Compress Coat QC Pack Finished Goods



Objectives:

•Customer Service

•Minimise Inventory

Objectives:

•Customer Service

•Minimise Inventory

Measures:

•# Stock Outs

•# Papers

Measures:

•# Stock Outs

•# Papers

KPIs




Exercise One•Run for ten Minutes•Review performance


MakeChanges

Exercise TwoExercise Two•Run for ten MinutesRun for ten Minutes•Review performanceReview performance


MakeChanges

Exercise ThreeExercise Three•Run for ten MinutesRun for ten Minutes•Review performanceReview performance



Exercise OnePush System


DispensaryCampaign size =6

GranulationCampaign size = 6Stores

CompressionCampaign size = 6

CoatingCampaign size = 6

PackingCampaign size = 6

DespatchSafety Stock = 6

Suppliers

Customers



How did you perform?•Customer Service?•Inventory?




What changes would you make ?What changes would you make ?



Kanban ~ Signal

There are three main types

Two Card Kanban• Move Card and Production Card

One Card Kanban• Production Card

Kanban Square• Marked out space on production floor



Two Card KanbanOften used when operations are some distance apart

Process 1Process 2

MoveKanban

Process 1 needs more material so sends a Kanban move card to process 2




Process 1Process 2

MoveKanban

The move card instructs process 2 to send so many of part x to process 1




Process 1Process 2

MoveKanban

The move card is exchanged with a production card to authorise process 2 to produce to replenish stock. The move card returns to process 1 with the material

ProductionKanban




Process 1Process 2

MoveKanban

Process 2 produces stock in line with the production card and then stops (untilanother move card is received)



One Card KanbanOften used when operations are close together

Process 1Process 2

Process 1 needs more material

ProductionKanban




Process 1Process 2

ProductionKanban

So it takes some stock and sends a Kanban production card to process 2 authorising production




Process 1Process 2

ProductionKanban

Process 2 replenishes its stock, returns the Kanban card and stops



Kanban SquareOften used when operations are close together

Process 1Process 2

Process 1 needs more material




Process 1Process 2

Process 1 takes materialThe empty square is authorisation for process 2 to make more product to replenish the square




Process 1Process 2

Process 2 stops and waits for the square to empty again



Kanban GuidelinesThe Kanban should describe where to get product from and how much to get

Only produce product as per the Kanban

The Kanban should be attached to the parts

Only fill the Kanban with 100% defect free product

Make the Kanban quantity as small as possible so that frequent communication of production activity is maintained between operations

Balance Kanban sizes to maintain flow

Sales and Production should agree the monthly production plan so that a level schedule can be created

The number of Kanbans should be gradually reduced in order to link processes better and reduce inventory and expose waste for improvement

Suzaki & Ohno 1987




MakeChanges



MakeChanges

Exercise Three•Run for ten Minutes•Review performance



DispensaryCampaign size = 3


CompressionCampaign size =3



DespatchSafety Stock = 3

Suppliers

Customers

KBKB

KB

KB

KB

KBKB

Exercise TwoPull System v1



What changes would you make ?What changes would you make ?




MakeChanges

Exercise Two•Run for ten Minutes•Review performance

MakeChanges





DispensaryCampaign size = 1


CompressionCampaign size =1



DespatchSafety Stock = ?

Suppliers

Customers

KBKB

KB

KB

KB

KBKB

Exercise TwoPull System v2



Lessons learned?Lessons learned?

The Kan Ban Game. 2 © The Delos Partnership 2003 To understand how Kanbans Aid the transition from...

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Transcript of The Kan Ban Game. 2 © The Delos Partnership 2003 To understand how Kanbans Aid the transition from...