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08/13/2012 09:42 AM
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Hi everyone,
I've read on this forum that kanban is a tool to expose the problems in the process flow. Could someone give me some examples what kind of problems could be exposed with kanban?
Thanks in advance,
Twinny
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08/13/2012 03:11 PM
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Twinny,
First of all, remember that Kanban represents inventory. By definition, all inventory is waste. So by its very nature, there's one problem Kanban exposes. Second, perfect single piece flow (at Takt) requires little or no Kanban. If you need more Kanban, it is generally to cover for problems.
Generally speaking though, one puts in a Kanban system to control inventory levels, but you have to start someplace - generally lots of Kanban. One of the rules of Kanban is to continuously remove Kanban, which will expose problems. Instead of putting Kanban back in, one needs to fix the problem, then remove more Kanban. And that is how Kanban exposes problems.
Tom
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08/13/2012 03:12 PM
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To name a few:
- Chronic parts shortages
- Lack of JIT delivery (to the floor)
- Lack of operator discipline (hoarding parts)
- Supplier issues (stuff arriving late to need)
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08/15/2012 04:44 AM
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Hi Twinny,
Kanban also provides you a vehicle for deliberately stressing a system, but in a controlled manner. If you kanban quantity is 10, you drop it down to 9 and see where the weakest link is. It might be quality, delivery times, or something else entirely. You may find that you need smaller order quantities from a supplier. The point is that you will, little by little, get rid of the barriers to flow.
Of course, as you lower the size, you will have to fix the problems that you uncover.
Good luck!
Jeff Hajek
Velaction Continuous Improvement
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08/16/2012 10:30 AM
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Jeff has identified strong points of Kanban. Another point to remember is that production needs to be consistent with the daily plan and be leveled to have the lowest inventory. If production falls short and the expected Kanban are not made available for reordering you could run out of material over the following week. This is one of the problems that Jeff has inidcated that you will have to fix.
Ron Turkett
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09/04/2012 10:47 AM
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Thomas, Ken, Jeff and Ronald. Thank you so much for the explanation!
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