Kanban Explained in 11 Slides

Kanban Explained(includes other processes besides picking component parts)

Kanban (“KAHN-BAHN”) – Japanese word meaning “signboard or billboard” – a scheduling system to ensure that only what is needed is produced

The general idea of Kanban

Supplier Customer

1. Customer logs an order in an order system

3. Supplier delivers exactly what the customer ordered

Order Information

2. Supplier pulls the order info to produce to the order

Each action is triggered by the delivery of the order itself, requiring less effort to manage the information and timing of tasks

Some different Kanban methods

Central information spot• “Kanban Board” – physical board showing order status• SharePoint Task List (tasks are “orders”)

Physical movement of a bin or card• Empty, labeled bin physically delivered to the supplier• Card with order information delivered to supplier

Example: Picking large sheet metal parts with forklift (at Kirby Risk Service Center)

Wow, sure glad I can drive this forklift…WITH MY MIND

Forklift Driver Parts pickerParts Picking Card

1. Parts picker writes up a sheet metal pick ticket

3. Forklift driver delivers part to job staging area

2. Forklift driver picks the part, and applies a label to it showing the KR Part #

Example: Kanban project board

Task owner Task Assigner

1. Project manager puts task post-it onto “Backlog” section of Kanban board

3. Task owner moves post-it to “done” (and notifies project manager, if it is hot)

Kanban Board

2. Task owner moves post-it into “In Process”, and works on taskBacklog In

Process Done

What it looks like:

CURL

YM

OE

LARR

Y

= regular task

= hot task

4. Team meets in regular accountability meeting to…• Discuss issues (interruptions, barriers to flow, etc.)• Problem solve together• Plan further action

Kanban Project Board, ctd.Close-up view of the board

Backlog In Process Done

CURL

YM

OE

LARR

Y

Color Code= regular task

= hot task

Example: SharePoint Task List

Task owner Task Manager

1. Task manager creates task in SharePoint list

3. Task owner marks task as “Complete”

SharePoint Task List

2. Task owner marks task as “In Process”

4. Task manager notified

How to make an electronic Kanban system actually work…make it visual!

In electronic systems, tasks can tend to get hidden in the sea of electronic inventory: folders, websites, spreadsheets, databases, etc. Here are some ways to make it visual…

1. Automatic email gets sent to task list manager when changes are made to a task

2. Regular process for task owners & task manager to check task lists3. When a task owner marks a task as “in process”, they make a note

which they visually display at their workstation4. Use dashboard(s) to draw together information from multiple info

sources to a single place

Products

Regular time increments (ex: 30 min)

Best Practices with physical Kanban bins

• Three-bin system – A bin is kept at the initial demand point, the inventory control point, and at the supplier

(bins have a removable card with product details and other needed information)

• Calculate just enough Kanban cards for each product

• Use a heijunka box: (a.k.a. load-leveling box)

http://en.wikipedia.org/wiki/Kanban

http://en.wikipedia.org/wiki/Heijunka_box

Info from:

Some rules used by Toyota

1. Do not send defective products to the subsequent process.

2. The subsequent process comes to withdraw only what is needed.

3. Produce only the exact quantity that was withdrawn by the subsequent process.

4. Level the production.5. Kanban is a means of fine tuning.6. Stabilize and rationalize the process.

Info from http://en.wikipedia.org/wiki/Kanban

How Kanban helps with common problems

Problem How Kanban helps

Bottlenecks / Multitasking / Task-switching

Helps process users to do one-piece-flow, which cuts down on WIP

People stressed because too much is demanded on them

Makes work visual, which naturally creates more accountability, and allows employees to better level out the work

Communication breakdowns Manages the communication task itself, so there’s much lower risk of forgetting to notify the people who need updates

“Just using Lean tools is like looking after an animal for years without knowing if it was a dog, rabbit, leopard or a sick rat” –Author Stephen Parry

Kanban is a great tool, but just like a hammer, there are times when it works well by itself to fix an obvious problem (ex: a nail sticking out of a cabinet), but there are times when a lot more than a hammer is needed (ex: improving on time delivery of cabinets). Kanban systems can help to improve the flow of information or products in a workcenter or team, but it is a tool that is best deployed aligned with a company-wide improvement program

And now for something completely different…

(Images from www.leanmemes.com)

Brent BrewingtonQuality Specialist

About the author:

Blog: QualityIdeasGuy.com Twitter: twitter.com/BrentBrewingtonLinkedIn: LinkedIn.com/in/BrentBrewingtonAbout.me: about.me/BrentBrewington

How I found my way into quality: While managing a Korean/Japanese restaurant serving Purdue students, I started to lean up the order management, production, and service processes, and realized that I wanted to do that for a living: improving processes and systems so that they are easier for people to use, and increase in performance. After doing some soul-searching and intense networking, I landed a job in quality at a tier one supplier to Caterpillar, and haven’t looked back since!

You are more than welcome to connect with me and get in touch. I’d love to listen to your ideas, and to share some of mine