kan ban & standardize work overview feb 2011

Kan Ban

Kanban : Pull System

Updated: June 2nd, 2006

2

Basic Principleof

KANBAN



3

Controls production of the right parts, in the quantities, at the right moment, in every stage of production.



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An instruction for: withdrawing products from the preceding processProducing the quantity that has been withdrawn



5

Two types of Kanban the Production Instruction Kanban (PIK) the Withdrawal Kanban (WK)


6 DEFINITION: kanban card = communication toolTARGETS: Indicate the part number / part name and the quantity to be produced per card Information on the card

- name of the supplier and name of the customer. - point of storage (shopstock) and point of use

KANBAN CARD



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Assemblyline

Withdrawal Kanban loop

a

b

c

b

PIK

Production instruction Kanban loop

B

A

a

b

C

c

B

A

a

b

C

c

A

a

Supermarket / shopstock

b

WKWK WK To internal customer

Batch Building BoxWK

From internal customer

Instruction Kanban (PIK)


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1. Production batch = 1 Kanban (no changeover) The production order for the reference. A 1 Kanban corresponds to 1 box to produce

2. Production batch = n Kanbans (changeover time) Kanban with batch-building box

Instruction Kanban (PIK)


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When different references are manufactured in the same process with changeover time, the production order is a pack of Kanban (a batch).The production order is not given until the batch has been constituted .

A batch of n Kanbans corresponds to n packaging units to produce. Example: The batch of five Production Instruction Kanbans is the production order.

Withdrawal Kanban


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The order for withdrawing the reference. It is used between sequencer and production line processes within a site to instruct the internal supply team to pick up the parts from upstream.

Withdrawal Kanban


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The downstream process at the end of the line

The sequencer at the end of the line

Circulation of this Kanban must follow two principles:

Simultaneous transfer of the parts and the corresponding information (the Kanban is attached to the packaging unit or part)

Frequent transfer (several times per shift – if possible once per hour)

Batch Building Box


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Batch Building Box


13

DEFINITION:

Is a box accumulating the kanban cards in order to build the batch The batch size reflect the flexibility of the production line / machine (Faurecia proposes to invest 10% of the production time in tool change)

The batch building box is placed at the end of the lineTARGET:

build a production batch with a fixed size


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DEFINITION:

reflect the flexibility and reliability of the machine / production line. This stock:*is designed to contain all product variants (or at least the most demanded)*is located at the end of the machine / production line.TARGETS:

allow the customer to pick the parts he needs without waiting the parts to be produced

END OF LINE STOCK

WAITING QUEUE


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The practical way of maintaining the withdrawal order of the packaging units.It represents the manufacturing sequence of the production line and uses gravity to feed the cards.


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DEFINITION: WQ helps to accumulate the batches respecting the FIFO The waiting queue is placed at the beginning of the production line

TARGET: give to the production a clear sequence to be respected for the production of the batches

WAITING QUEUE

6 Rules for Effectiveness


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No bad part may reach next process The number of parts in each packaging

unit must be identical to the number of parts noted on the kanban

The downstream process must withdrawal according to the kanban the exact quantity of the right product at the right time

6 Rules for Effectiveness


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The output of the upstream process must match the quantity withdrawn by the downstream process

The number of Kanbans must been reduced. The number of PIK reflects the stock

levels. It is essential to lower the kanban as progress is achieved.

The Kanbans must be used to adapt to fluctuations in demand

ADVANTAGES


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• Respect the customer demand• Produce at the rythm of the customer (Takt Time)• Visualisation of the production management• Regular and controlled production• Improve the reactivity



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• Video“Palmela Fixed Batch Kanban”• Kanban Pull Systen Model – Simulation• Shopfloor visit: waiting queue, batch building box, kanban

Standardized Work

Production System Effiency

STANDARDIZED WORK

TRAINING

Definition – Standardized Work

A timed description of the best possible succession of basic manual tasks for an operator.

It includes:- transformation and control operations- but also movements - other necessary steps included in the cycle time.

Objective

Achievement of safety, quality, productivity and delivery performance objectives through:• reduce dangerous movements• apply controls and ability to repeat• correct use of machines• identification and elimination of the 7 wastes• training and evaluation of the operators

Key Factors•Allows the repeatability of the sequence of basic tasks during each cycle with low variability of the process.•Work content may differ according to product options• Separate the man and machine• Reduce frequencial operations (reduce variability)• Quick and efficient treatment process of improvement ideas through the operator

Cycle Time and Takt Time

Takt time is a rate that represents, in seconds, the number of parts the customer expect us to deliver

Cycle time is a rate, in seconds, at which the product must be produced in order to offset “waste” in the system and achieve the Takt Time needed to satisfy the customer

Work ContentSum of the basic tasks carried out at each workstation to obtain a complete and good product (amount of work for a part)It is measured by timing the cycle of each operator using a cycle time measurement form. The measurement must be based on 20 consecutive cycle times (everything included). Time necessary for self-inspection has to be included.For each operator, we will show the minimum time, wait time excluded, as well as the maximun and mean time.

FORMS

The standardized work goal is based on 3 forms:• Standardized Work Chart ( #)• Work Combination Table (#)• Standard Operation Sheet (#)

Standardized Work Chart- describes the succession of basic tasks and the position of the operator for each of them. - helps to visualize easily the operator movements and to identify useless movements- determines the number of parts between each workstation.

Standardized Work ChartOperation from: Date:

to:

Takt Time Expected nb parts waiting

61 s

Cycle time

51 s

Expected number of parts waiting

3

FAU-F-PS-5006 /1

Product: panel Process: welding, assembly

Standardized work chart

Machine 4 (Welding)

Station 5 (Inspection)

FP cart12

3

4

5

6

710

8

9

Qualityinspection

Safety

Movement

with part

without part

Productionname:

date:

Methodsname:

date:

Qualityname:

date:

Sketch operator's workstations. Break his/her work down into elementary tasks corresponding to those in the standard w ork combinaison table.

Number the operator's position for each job

Add symbols

Part awaiting operator (e.g. At end of cycle)

Special hasard or safety action

Work Combination Chart- gathers all the basic identified tasks on the Standardized Work Chart and details each specific time.- helps differentiate times walking and waiting from working on the workstation. - allows to evaluate the difference between cycle time and takt time and to verify that operators do not wait for the machine.

Work Combination Chart

/ / / / / /

SYMBOLS: - MANUAL: AUTO: WALK: IDLE:15

PRODUCT REFERENCE NUMBER:

WORKSTATION ANALYZED BY:

TAKT TIME: Quality

Volume:

DATE:

Production Methods

STANDARDIZED WORK COMBINATION TABLE

TIME OPERATION TIME

WALKAUTOMANUOPERATION NAME

N° 45 60

2

3

15TOTAL

35

30

3

2

310Position part for inspection

Pick waiting part

2Position part

1

5

4Functional inspection 3

15

Place part in cart

3 Weld

Welding inspection

2

3

9 Pick welded part

2

7 Pick inspected part 2

Surface inspection

5

6

8

3

50

3

34

25

2

555 10 40302015

FAU-F-PS-5007 /1

CT = 51s

TT = 61s

Record time spent on:- manual operations - automatic operations- walking (1m = 1s)

Break work down into elementary tasks, numbered as in the standard work chart

Represent the times graphically, differentiating among:- manual time ( ______ )- automatic time (-----)- walking (~~~~)- idle time (====)

Standard Operation Sheet- details all the instructions to realize an operation at a workstation describing it by the safest, easiest and most efficient way.- contrary to the standardized work chart and work combination table relative to an operator, this document is linked to a process or a basic operation from the process.

Standard Operation Sheet

Fig 1.

Fig 2.

Fig 3.

Bolster

Name:

= SAFETY = QUALITY = TIP

STANDARD OPERATION FAU-F-PS-241 / ENversion 02

Part Number xxx Part Name

SKILLEDOPERATOR

Non Conforming Product:Approved Signature/DateIssued Signature/Date Checked Signature/Date

Name: Name:

5 Place one white & green clip into cavities 3&4

- Take one white & green LH clip from the dispenser.- Place the green clip into the center clip position and the white into the bottom location on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl

P lace rejects in reject container. Record on P rocess M onitor Sheet. If 3 or more rejects found with same fault call Gap Leader.Function: Function: Function: Name:

Signature/Date

3 Fold waste and place onto to stand.

Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).

4Remove the spiked frame from the underneath bench

Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)

Ensure that the handle is pointing towards you is fully located against the censor

1 Remove parts from tool Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)

2Remove the spiking frame from the upper tool

Remove the waste then place the frame onto the bench

Ensure frame handle is pointing away from you and spikes are pointing upwards.

Page No: 1/1

No. Operation 30 Sec Sketches / Photo's / etc.

Line : EQ Bolster Work-station: Woodstock

Plant: Washington Document No.: xxxxRevision Level: 4

Cavities

Spiking frame

Cavities

234 1

Granulator

Cooling stand

White

GreenWhite

1 2

3

4

5

Safety issue: to be used if a real riskexists for employees !

Important remarks can be written in bold or underlined

Operator who participatedin setting up the Standard Operation

Non-ComformanciesReaction rules have to be adapted to the workstation

Tip : put the stress on special comments

Whole Time needed according to the Standardized Combination Table

big fontenables operator to read from worstation

"Alt+Enter"to go on the next line in the same cell

Self-Quality check

Time:

Standard Operation Sheet

Fig 1.

Fig 2.

Fig 3.

FAU-F-PS-241 / ENversion 02

Function:

5 Place one white & green clip into cavities 3&4

- Take one white & green LH clip from the dispenser.- Place the green clip into the center clip position and the white into the bottom location on cavity 4.- Take one white & green RH clip from the dispencer.- Place the green clip into the center cl

Signature/Date

4Remove the spiked frame from the underneath bench

3 Fold waste and place onto to stand.

STANDARD OPERATION

Fold the waste from the frame and place it onto the granulator cooling stand, using it to push the existingwaste into the granulator (fig 2).

Remove cavities 3 & 4 from the mould tool.Place parts onto left side of bench (Fig1)

2Remove the spiking frame from the upper tool

Sketches / Photo's / etc. = SAFETY = QUALITY = TIP

Remove the waste then place the frame onto the bench

Ensure frame handle is pointing away from you and spikes are pointing upwards.

Signature/Date Signature/Date

xxxx4

1/1

Document No.:

Revision Level:

WoodstockWashington

Work-station:

Plant:

P lace rejects in reject container. Record on P rocess Monitor Sheet. If 3 or more rejects found with same fault call Gap Leader.

Name: Name:

Non Conforming Product:

Function:

Signature/DateIssued Checked

Name:Function:

130 Sec

Remove parts from tool

Operation No.

Remove the spiked frame from underneath the bench place it into the guides on the upper mould tool (fig 1)

Ensure that the handle is pointing towards you is fully located against the censor

SKILLEDOPERATOR

ApprovedName:

xxx Page No:

Part Number

Part Name Line :Bolster EQ Bolster

Cavities

Spiking frame

Cavities

234 1

Granulator

Cooling stand

White

GreenWhite

1 2

3

4

5

Time:

Standardized Work

kan ban & standardize work overview feb 2011

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