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Système Excellence Faurecia Faurecia Excellence System

Production System Efficiency

Basic principles of KANBAN

Contents
1- Functions of Kanban: produce and withdraw 2- Withdrawal Kanban (WK) 3- Production Instruction Kanban – without production batch 4- Production Instruction Kanban – fixed production batch 4.1- with batch-building box 4.2- triangular Kanban 5- Six rules foreffectiveness 6- Kanban: visual management 7- Other cases

Introduction

Kanban is an information system that controls production of the right parts, in the right quantities, at the right moment, in every stage of production. One of the most important concepts in a lean production system is the splitting of production batches. Kanban is a simple and reliable system for managing the great number ofproduction orders which this splitting generates. Kanban requires smoothing demand and creating shopstock. The purpose of this document is to describe how Kanban operates.

Document for internal use only

FAU-S-PS-5023/En version 1

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1- Functions of Kanban: produce and withdraw
The Kanban is an instruction for: ü withdrawing products from the preceding process ü producing the quantitythat has been withdrawn. Thus, there are two types of Kanban: the Production Instruction Kanban (PIK) and the Withdrawal Kanban (WK).

PIK

a Upstream process a b c b
b

a a

WK

a A b B c C

a A b B c C End of line

a A

a A A b B Downstream process

c C

a

c C
Line supply

Production Instruction Kanban (PIK)
1. Production batch = 1 Kanban (no changeover time) This Kanbanis the production order for the reference. A 1 Kanban corresponds to 1 box to produce.

PIK

2. Production batch = n Kanbans (changeover time) Kanban with batch-building box When different references are manufactured in the same process with changeover time, the production order is a pack of Kanbans (a batch). The production order is not given until the batch has been constituted. A batch ofn Kanbans corresponds to n packaging units to produce. Example: This batch of five Production Instruction Kanbans is the production order.

PIK

Withdrawal Kanban (WK)

WK

This Kanban is the order for withdrawing the reference. It is used between processes within a site to instruct the internal supply team to pick up the parts from upstream.

Document for internal use onlyFAU-S-PS-5023/En version 1

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2- Withdrawal Kanban (WK)
This Kanban is used between processes: ü the downstream process the end of the line ü the sequencer and the end of the line Circulation of this Kanban must follow two principles: ü Simultaneous transfer of the parts and the corresponding information (the Kanban is attached to the packaging unit or part) ü Frequent transfers (several times pershift— if possible, every hour) PIK End of line a WK 1 a a A Upstream process b B c C a A b B c C a A 2 a A A
Withdrawal direction

b B c C
Line supply

Downstream process

c C

3 a

1. The handling operator takes a Withdrawal Kanban removed from a packaging unit from the previous process. 2. At the end-of-line stock location indicated by the Kanban, the operator swaps the WithdrawalKanban (WK) for the Production Instruction Kanban (PIK). In other words, s/he takes the Production Instruction Kanban (PIK) off of the box, puts the Withdrawal Kanban on the box and brings the Production Instruction Kanban to the line’s queue or batch-building box, depending on the case. 3. The operator then takes the box with the Withdrawal Kanban and delivers the parts to the supply zoneindicated by the Kanban. Notion 1: End of line The products generated by the Kanban system are stocked at the foot of the line, in the immediate vicinity of the supplier’s production lines. This placement permits visual stock control. End-of-line stock is managed FIFO and there is usually one color per reference. It is also called Shopstock.

Document for internal use only

FAU-S-PS-5023/En version...