Pull Production System kanban

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Pull Production SystemKanban

• Presented by 20
  July 2016
• ADNAN ALI
• Bachelor in Mechanical Engineering
• Politecnico di Torino
• Thesis Supervisor
• ALESSANDRO CHIARAVIGLIO
• Department of Management and Production (DIGEP)
• Politecnico di Torino

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Index

• Pull Production System
• Push Production System
• Pull Production System Kanban
• Methods of Kanban
• Functions of Kanban
• Types of Kanban
• Kanban Cards
• Conclusion

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Pull System
Definition A method of controlling the flow of
resources by replacing only what has been
consumed.
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Push System
Definition A method in which resources are
provided to the consumer based on forecasts or
schedules.
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Push vs. Pull
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The Material Dilemma
Counting Parts
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Replace Consumption
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KANBAN

• Kanban means card or visible record or
  signboard in Japanese refers to cards used to
  control the flow of production through a factory.
• KANBAN is a PULL System

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Function of Kanban

• The key objective of a Kanban system is to
  deliver the material just-in-time to the
  manufacturing workstations, and to pass
  information to the preceding stage regarding what
  and how much to produce.
• A Kanban fulfills the following functions
• Visibility function The information and
  material flow are combined together as Kanban's
  move with their parts (work-in progress,
  WIP).
• Production function A function which indicates
  the time, quantity, and the part types to be
  produced
• Inventory function Which measures the amount
  of inventory

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The Kanban Method

• The Kanban Method is an approach to incremental,
  evolutionary process and systems change for
  organizations. It uses pull system as the core
  mechanism to expose system operation and improve
  the system.
• The Kanban Method is rooted in four basic
  principles
• Start with existing
• The Kanban method starts with existing roles and
  processes and bring continuous changes to the
  system. The Kanban method is a change management
  method.
• Agree to pursue incremental, evolutionary change
• Incremental and evolutionary change is the way to
  make system improvements and make them stick.
  Sweeping changes may seem more effective but have
  a higher failure rate due to resistance and fear
  in the organization.
• Respect the current process, roles,
  responsibilities and titles
• The Kanban method seeks to drive out fear in
  order to facilitate future change. It attempts to
  eliminate initial fears by agreeing to respect
  current roles, responsibilities and job titles
  with the goal of gaining broader support.
• Leadership at all levels
• Acts of leadership at all levels in the
  organization, from individual contributors to
  senior management, are encouraged.

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KANBAN PROPERTIES

• Kanban is based on five core properties
• Visual workflows
• Work in progress (WIP) limits
• Enhanced workflows
• Agreement on process policies
• Data-driven collaborative improvement.

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TYPES OF KANBAN

• Primary Kanban
• Supply Kanban
• Procurement Kanban
• Subcontract Kanban
• Auxiliary Kanban

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KANBAN CARDS

• The core functionality of a Kanban card is to
  visually convey a work items progress as it
  flows through a system or process. While not
  intended to replace the need for conversation,
  using cards on a Kanban board as the teams
  central information hub can reduce time spent in
  status meetings, introduce more high-value
  collaboration opportunities and improve overall
  efficiency.
• Kanban cards can help teams
• Gain a quick understanding of work item details
• Facilitate handoffs between team members as the
  work progresses through different stages in the
  teams process
• Document critical information
• Record important work attributes and metrics that
  you can use later to help improve your workflow

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CORE ATTRIBUTES OF A KANBAN CARD

• As Kanban emerged as a system in knowledge work,
  the kanban card came to represent an individual
  work item. These pieces of work are typically
  displayed in the form of sticky notes on a
  whiteboard that uses lanes to show the steps in a
  teams process.

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FACE OF KANBAN CARD

• The face (or front) of a Kanban card presents
  details that are relevant to the team, such as a
  unique identifier or title, a brief description
  of the work, a rough estimate of the size of the
  work, and whos been assigned to it.

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BACK OF A KANBAN CARD

• As a Kanban card moves through the workflow, team
  members can use the back of the card to record
  applicable metrics (e.g., start date, blocked
  days, blocked location, finish date, and lead
  time)

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CONCLUSION

• But why Kanban?
• because
• it helps in visualising the system and expose
  problems
• it allows us to evaluate the impacts of process
  changes
• it allows us to identify bottlenecks and
  alleviate them
• it allows us to establish trust in the process
• it helps us to maintain a sustainable pace with a
  sustainable throughput
• you need to relax and Kanban advocates just that!

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Thank you