KANBAN

The Idea Smith

 KANBAN- AN INTRODUCTION

 A system of continuous supply of components and parts

such that workers have what they need, where they need
it and when they need it.
KAN VISUAL
BAN SIGNAL

 Kanban is a method for developing products with

emphasis on just in time manufacturing process in which
movement of material through a process are recorded on
specially designed cards.

 Kanban limits the amount of inventory in the process by

acting as an authorization to produce less inventories
 KANBAN SYSTEMS

 A Kan-ban is a card containing all the information required to be

done on a product at each stage along its path to completion and
which parts are needed at subsequent processes.
 These cards are used to control work-in-progress production, and
inventory flow. A Kan-ban System allows a company to use Just-
In-Time Production and Ordering Systems that allow them to
minimize their inventories while still satisfying customer
demands.
 KANBAN- THE PULL SYSTEM

Method of controlling
and balancing of the
flow of resource.
Eliminating waste of
handling, storage,
rework and minimize
WIP.
Manufacture and ship
only what has been
consumed.
Provides visual
control of all
resources
 MERITS…

 Lead Time is kept to a minimum.

 Highest quality
 Optimize inventory, reduce & only consume what is needed.
 Defective products will not be sent to downstream process.
 Reduce waste and scrap.
 Provides flexibility in production.
 Increase output.
 Reduce total cost.
 Accountability and perfect shipping.
MAKE EVERY THING TRANSPARENT
 STEPS TO IMPLEMENTING KANBAN

 Conduct data collection

 Calculate the Kanban size
 Design the Kanban
 Train everyone
 Start the Kanban
 Audit and maintain the Kanban
 Improve the Kanban
KANBAN- THE PULL SYSTEM
KANBAN SQUARES
 HOW IT WORKS?

 Super Market
 WIP Board
 Containers
 Kanban boards
 Kanban cards
 Kanban post
 Kanban loading and Input book
SUPER MARKET

 The area that stocks goods

in the finished form or in
the WIP form.
 It exists between cutting
and sewing, sewing and
finishing and also in
finished goods ware house.
 It ties the consuming and
supplying process in a pull
system.
 WIP BOARDS
 A l l d et ails r eg ar ding cu t t ing an d s ew i n g ar e d i s plays i n b o ar ds i n - front o f
s u p er mar k et f o r eas y acces s o f each d ep artment an d f o r p er f ect p l an ning .
KANBAN CARD

 Inventory for items is

authorized by Kanban Cards
and these are recycled
through the production
system continuously.
 It identifies the Style No,
Line No, Kanban No, Color,
Size and Quantity issued .
 Kanban cards serves as both
transaction and
communication device.
 DIVERSITIES IN KANBAN

 BLUE : when bit parts are available in

cutting.
 WHITE : when packing list is adhered.
 PINK : when packing list is not
adhered.
KANBAN BOARD

 its a Visual display

board(use magnets,
plastic chips, colored
washers, sticky notes
etc…)
 The accumulation of
cards contains till a
predetermined number
of cards are achieved.
KANBAN INPUT BOOK AND
LOADING BOOK
 Kanban loading and
Input Book for
Kanban card which
keeps the record of
loading Kanban to the
batch and completion
of that Kanban.
 By observing the two
books anyone can
find the loaded
quantity, WIP of the
line, which Kanban is
taking much time to
operate.
 KANBAN CALCULATION

1 Kanban+Number of Workstation
X 5 Units + 1 Kanban
Example, 32 WS X 5 units = 160 Units
Kanban Size = 60
Therefore, 60 + 160 + 60 = 280/60 = 4.6 = 5 Kanban

Minimum of 3 Kanban should be kept ready in cutting for ready to

load and cutting section should display WIP Kanban on the cutting
table.
 RULES OF KANBAN

 1) Downstream process may only withdraw items in the

precise amounts specified on the Kanban.
 2) Upstream process may only send items to downstream
process only in the precise amount and sequences specified
by the Kanban.
 3) No items are made moved without a Kanban.
 4) A Kanban must accompany each item at all times.
 5) Defects and incorrect amounts are never sent to the next
downstream process.
 6)The number of Kanban should be monitored carefully to
reveal problems and opportunities for improvement.
 RESPONSIBILITIES

 Floor Planner – Preparation of line plan for the

factory after order allocation by central planning.

 Cutting Manager / In-charge – Creating Micro-cut

plan and Kanban Plan for each Item, PO and Color
along with Priority. Distributing the same list to
bitting, washing, sewing and finishing for follow-up.

 Loader – Updating line loading book with Kanban

Stickers and ensuring exact quantity is fed to the lines.
 RESPONSIBILITIES

 Production Managers – Getting the pieces, loaded as per

Kanban, stitched, finished and audit passed within
specified time. Handing over the pieces as per Kanban to
Finishing In-charge after audit clearance.

 Supervisors – Solving line issues, getting alterations done

before that specific Kanban is finished, getting rejected
pieces re-cut and stitched to complete the pieces loaded as
per Kanban.

 Finishing In-charge – Receiving the pieces as per Kanban

from the lines (after audit pass only). Storing the pieces in
respective areas. Sealing of Kanban as a proof of goods
received and updating the Carton Tracker to update the
status of shipment
 CONSTRAINTS IN ADHERING KANBAN

 Predictability and visibility of plan and stock.

 Labor absenteeism.
 Re-cutting.
 Quality issues.
 Micro cut plan should be accurate.
 Remove the problem of lost cards.
 Premature commitment should be avoided.
 Time & effort needed for Kanban card handling should be
minimized.
 FUTURE UPGRADATION

 The complete success of application of Kanban in the

extensive run depends on close understanding between the
management and executives. The feedback , analysis and
suggestion based on the current scenario will leads to the
version 2.
 THE END
(REALLY ON THE BEGINNING…)