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1 [email protected] Delivery Kanban Principles Foundation of a Pull System Marek Piatkowski – July 2012
Delivery Kanban Principles Foundation of a Pull System Marek Piatkowski – July 2012
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
The Supermarket Suppliers
Food Mart
Supermarket
Warehouse
Supplier Supplier
Stockroom
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
Kanban means Visual Signal
Material Delivery - Kanban Card
A visual signal to replenish materials consumed in a lean process. Signal = Card or Label
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.
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
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
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
