Different industries require different Kanban applications. Carefully study and understand the following content, combine it with actual work, practice and explore, and sort out a practical Kanban management plan.
Types of Kanban
The essence of Kanban is an information medium that issues production instructions to the required parts and components in the required quantity at the required time to achieve this function The form can be various. Kanban boards are generally divided into three categories: transfer kanban boards, production kanban boards and temporary kanban boards. 1. In-process kanban In-process kanban refers to the kanban used when a certain process is being processed. This kind of kanban is used in assembly lines and processes that do not require substantial job change time (job change time is close to zero) even if multiple products are produced, such as machining processes. 2. Signal Kanban Signal Kanban is a Kanban used between processes where batch production has to be carried out. For example, resin molding process, die forging process, etc. The signal signboard is hung on the products produced in batches. When the quantity of the products in the batch is reduced to the reference number, the signboard is removed and returned to the production process. The production process then starts production according to the instructions of the signboard. In addition, signal boards can also be used to instruct distribution from parts delivery to the production process. 3. Inter-process kanban The inter-process kanban refers to the kanban used within the factory when subsequent processes go to the previous processes to receive the required parts. In a typical inter-process kanban, the previous process is component line 1. The assembly line 2 of this process requires parts numbered A232-60857. According to the kanban, you can go to the previous process to collect them. 4. Outsourcing kanban The outsourcing kanban is a kanban used by external collaborating manufacturers. Information such as the name of the purchasing unit, purchase time, quantity of each purchase, etc. must be recorded on the external ordering board. The outsourcing kanban is similar to the inter-process kanban, except that the "previous process" is not an internal process but the supplier. Through the outsourcing kanban, it is slowly pulled forward from the last process to the supplier. Therefore, sometimes companies will require suppliers to also implement JIT production methods. 5. Temporary Kanban Temporary Kanban is a Kanban used when equipment maintenance, equipment repair, temporary tasks or overtime production are required. Different from other types of kanbans, temporary kanbans are mainly used to complete unplanned production or equipment maintenance tasks, so they are more flexible.
Practice of using kanban boards
(1) How to use kanban boards There are several types of kanban boards, so the methods of using kanban boards are also different. If the method of using kanban is not carefully formulated, production will not proceed normally. From the method of using kanban, we can further understand the uniqueness of the JIT production method. When using kanban, each transfer kanban only corresponds to one kind of component, and each component is always stored in the specified and corresponding container. Therefore, the container corresponding to each delivery kanban is also certain. 1. How to use kanban in a process The most important point in using kanban in a process is that the kanban must move with the physical object, that is, with the product. When picking up intermediate products in the post-process, remove the intra-process signboard hanging on the product, and then hang the inter-process signboard for collection. The process then proceeds with production in the order in which the kanbans are removed and the quantities represented by those kanbans, stopping production if the quantity of kanbans removed becomes zero, so that there is neither delay nor excess storage. 2. How to use the signal signboard The signal signboard is hung on the products produced in batches. If the quantity of the product in the batch is reduced to the reference number, the kanban will be removed and sent back to the production process, and then the production process will start production according to the instructions of the kanban. If it is not delisted, it means that the quantity is sufficient and no reproduction is needed. 3. How to use the inter-process kanban The inter-process kanban is hung on the box of the parts received from the previous process. When the parts are used, the kanban is removed and placed in the kanban recycling box installed at the work site. The inter-process kanban in the recycling bin means "This part has been used, please replenish it." On-site managers come regularly to collect the signboards, collect them and then distribute them to the corresponding pre-processes to collect the parts that need to be replenished. 4. How to use outsourcing signboards: The removal and recycling of outsourcing signboards are basically the same as the inter-process signboards. After recycling, they are separated according to the collaborating manufacturers. When the collaborating manufacturers come to deliver the goods, they will take them back and become the production instructions for the next production of the factory. In this case, the purchase of this batch of products will be delayed at least once.
Therefore, it is necessary to issue the corresponding number of kanbans according to the number of delays, so that the cycle can be carried out according to JIT. (2) The process of using kanban to organize production. JIT is a pull-type production. Information is transmitted through kanban, and the process is pulled step by step from the last process to the previous process. There are three processes in the production process. Information is transmitted from the entrance storage of the third process to the exit storage of the second process. Information is transmitted from the entrance storage of the second process to the exit storage of the first process. The first process receives raw materials from its entrance storage area to the raw material warehouse. In this way, the entire production process is organized organically through Kanban. (3) Other visual methods for issuing production requests instead of kanban. The form of kanban is not limited to a certain card form that records various information. In the actual JIT production method, there are many ways to issue production requests instead of kanban. Visual methods such as colored ping pong balls, empty containers, ground space markings and signal signs, etc.
Kanban management implementation
Kanban management implementation operation process: 1. When an abnormality occurs at the workstation (equipment, quality, materials, engineering, etc.), the operator presses the button to trigger a wireless alarm button; 2. Relevant responsible personnel (QC, materials, machine repair, etc.) can receive abnormal work station information through the mobile Bp machine. The system automatically records the abnormal alarm time point, and at the same time displays the abnormal work station information on the computer screen or LED billboard. and the alarm timer starts and a voice reminder is played. 3. When the relevant person in charge responds to the scene and presses the start processing button, the system automatically records the response time point, and the screen shows that the station processing is in progress; 4. After the relevant person in charge completes the processing, press the processing end button, and the system automatically records the end of the processing time point, clear the corresponding alarm information on the screen. Kanban management implementation function: Install 3 point extension wireless alarm buttons at the work station (alarm button + start processing button + processing end button). The system can collect statistics on equipment exception occurrence time, processing start time, and processing end time. Conduct personnel supervision and assessment. The goal is to reduce the incidence of related exceptions and improve response speed and execution efficiency.