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KANBAN SYSTEM CONCEPT
A kanban is usually a physical card that signals a specific event. There are two kinds of kanban. The “move kanban” is used to request parts from someone who will pull those specific parts and that specific quantity from a storage location such as a parts supermarket. The kanban indicates the consumption of material so that as the parts get used, the operator gets exactly the parts they need, no more and no less.
The “production kanban” is used to signal the start of production for a part. When parts are consumed either through the parts supermarket or directly from the downstream process, a certain unit of consumption would trigger a production kanban card to be sent back to the producing process. This tells those in the process what and how many they need to produce.
Each kanban card carries with it assumptions that everyone who touches them will understand. Those assumptions or rules (different than the 4 rules) are as follows:
1. The subsequent process should withdraw the necessary products from the preceding process in the necessary quantities at the necessary point in time.
2. The preceding process should produce its products in the quantities withdrawn by the subsequent process.
3. Defective products should never be convened to the subsequent process.
4. The number of kanban cards should be minimized.
5. Kanban should be used to adapt to small fluctuations in demand.
Each card, whether a production type or move type, should contain all of the needed information by BOTH the request and responder to complete this task. This is not limited to but must include part name or number, quantity per card, location to be picked up or produced, location to be delivered or consumed, and the number and total number of cards in the system (i.e., 2 of 6 cards).
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