Kanban for BFL

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    KANBAN Study

    BFL

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    - Need for KANBAN at BFL

    - What is KANBAN

    - KANBAN System An Overview- Benefits

    - Implementation steps Summary

    - KANBAN walk

    CONTENTS

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    GRINDING OPERATION WAS THE

    BOTTLENECK

    * On a 3-shift basis

    Soft Module

    Capacity: 1200

    parts/month

    Grinding

    Module

    Capacity: 940

    parts/month

    Final Module

    Capacity: 1500

    parts/month

    Dispatching

    Need for KANBAN

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    - Need for KANBAN at ALB

    - What is KANBAN

    - KANBAN System An Overview- Benefits

    - Implementation steps Summary

    - KANBAN walk

    CONTENTS

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    KANBAN DEFINED

    KanbanSystem is an information system that harmoniously

    controls the production of the right products in right quantitiesat right time in every process of a factory and also among

    companies.

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    OBJECTIVES OF KANBAN

    There are four objectives of KANBAN

    1.Convey information (what and when to produce,

    when and where to move)

    2.Control inventory (fixed total quantity of parts)

    3.Control process (visual are Kanban moving?)

    4.Support improvement (gradually reduce no. ofKanban)

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    TYPES OF KANBAN

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    - Need for KANBAN at ALB

    - What is KANBAN

    - KANBAN System An Overview- Benefits

    - Implementation steps Summary

    - KANBAN walk

    CONTENTS

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    KANBAN AS IMPLEMENTED IN GEARS

    A Mix of Production instruction

    and parts withdrawal Kanban

    Is designed to reduce Forced idle

    time due to No Material

    System owner is PPC, works in

    co-ordination with production

    Trigger is based on PPC plan atcomponent-machine level

    C id ti hil i P d ti

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    Considerations while preparing Production

    Plan

    PPC will develop and control the production schedulestarting with the final operation (J7/J9)

    Capacity variations at each stage i.e. Jr-4, Pin-1&2 &

    Jr-3.

    Manpower availability. Variety of Dies.

    Maintaining of Mini Mkt. stock for avoiding the stock

    out situation for Jr-4.

    WIP norms

    Availability of Shot Blasting output

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    KANBAN METHODOLOGY

    PPC makes the date wise and shift wise KANBAN

    plan as per the date wise Mfg Plan. As per the KANBAN plan, scheduling is done on

    KB posts in Grinding Module

    Material is made available for machining, 1 shift in

    advance at the appropriate machines.

    Production, produce the components and attach

    KANBANs to them as per color coding in

    respective lines.

    PPC moves the material with KANBANs.

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    KANBAN Card Samples

    PRODUCTION KANBAN

    PART VISUAL

    Trolley type

    No. of pcs

    A

    10

    SOFT MACHINING

    Part No.

    Part Name

    F1607811

    3rd on MS

    PRODUCTION KANBAN

    PART VISUAL HARD MACHINNG

    Part Name No. of pcs 10

    Part No. Trolley type B

    WITHDRAWAL KANBAN

    Storage

    Location

    Point of

    use

    PART VISUAL

    Part Name 3rd on MS No. of pcs 10

    Part No. F1607811 Trolley type A

    A

    A

    Crank Shaft

    D-3306

    3rd on MS

    F1607811

    Turn Blank Store

    3rd on MS Cell

    3

    Jr. Semi Finish

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    KANBAN Card Samples

    PRODUCTION KANBAN

    PART VISUAL

    Trolley type

    No. of pcs

    A

    10

    SOFT MACHINING

    Part No.

    Part Name

    F1607811

    3rd on MS

    PRODUCTION KANBAN

    PART VISUAL HARD MACHINNG

    Part Name No. of pcs 10

    Part No. Trolley type BA

    3rd on MS

    F1607811

    A

    Crank Shaft

    D-3306

    3

    Jr. Semi Finish

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    KANBAN POST

    Kanban Post is used as visual display for

    triggering Production.

    Kanban drop box

    Production

    Schedule

    Key Timings

    Production Area

    Description

    Grinding Module

    Die No-

    3306/3307/3295

    KANBAN

    Procedure

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    KANBAN Trolley distribution

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    KEY TIMINGS

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    - Need for KANBAN at ALB

    - What is KANBAN

    - KANBAN System An Overview- Benefits

    - Implementation steps Summary

    CONTENTS

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    KANBAN IMPLEMENTATION STEPS (1/2)

    DetailsStep

    Decision of

    Material

    Information

    flow

    Design of the

    Kanban

    resources

    Calculations ofResources

    Decision of

    layout

    Study of existing flow, identify stages

    Decide the flow type and flow stages Decide mini-markets stages and sizes

    Cards color and format

    Trolley type and color

    Stores for card

    Calculate the requirement of the following Cards & its Storage

    Trolleys

    Kanban boards and posts

    Collection boxes

    Mini-market areas

    Input material area

    Kanban post physical location

    Material flow routes

    Decision on

    Kanban

    Mechanics

    Weekly micro level planning of M/C Loading

    Key timings for material movement

    Batch sizes for material movement

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    DetailsStep

    Decision on

    Kanban

    Mechanics

    Training of

    executives and

    associates

    Prepare roll-out

    plan

    Monitor and

    improve

    Weekly micro level planning of M/C Loading

    Key timings for material movement Batch sizes for material movement

    Train line executives and associates

    Train associated lines executives and

    associates

    Train material handlers

    Prepare rollout plan, stage-wise is preferable

    Monitoring by

    Daily checks

    Periodic audits

    Problem solving and moving ahead

    Roll out in other areas

    KANBAN IMPLEMENTATION STEPS (2/2)

    Order

    resources as

    per rollout plan

    Order resources

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    - Need for KANBAN at ALB

    - What is KANBAN

    - KANBAN System An Overview- Benefits

    - Implementation steps Summary

    CONTENTS

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    KANBAN METHODOLOGY

    KANBAN BOARD will made available near to Jr-4

    & Jr-3. KANBAN BOARD will contain two cards with

    different colors, one card (Production card) will

    authorizes production on Jr-4 & another card

    (Move card) authorizes movement of palletcontaining Jr-3 output parts to supermarket while

    moving pallet to supermarket need to detach

    production card Jr-4 begin to produce another

    standard pallet to replace the one that was justtaken.

    Production card on Jr-4 need to be planned for SF

    & J7/J9 after completion of every 36 parts.

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    KANBAN METHODOLOGY

    No of move card depends on set-up change on Jr-

    4 (SF to J7/J9), because when set-up changes Jr-3output will be consumed by Jr-4.

    When IP for J7/J9 were moved from supermarket &

    consumed on Jr-4 operator will need remove the

    move card and need to keep in drop box availableon KANBAN BOARD.

    Material handler returns cards to appropriate

    KANBAN BOARD.

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    KANBAN METHODOLOGY

    Jr-4 (J7/J9)Jr-4 (SF) Jr-3Pin1&Pin2

    Sup

    ermarket

    Sup

    ermarket

    MATERIAL FLOW

    INFORMATION FLOW

    Move Card

    Production

    Card

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    Thank You