Scheduling with Kanban

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Last update: March 3rd, 2010
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Scheduling and Kanban systems

Kanban

In the supermarket system, we have seen example of a kanban driven production system, dedicated to a single product.

Here is a more elaborated supermarket holding three different references, each having its kanban.

Production operator receives "orders" through kanban cards returned after consummer picked his goods in the supermarket.

Kanbans are placed to be visible, on a scheduling panel per product type. The operator understands visualy that MAUVE products are less numerous in stock, consistently with the rule: one kanban = one product. Conversely, if kanban is on the panel, it is not on the product because it has been sold.

The operator will changeover production to manufacture two MAUVE units, and if nothing changes, change again for one ORANGE unit, whichdont kanban is.. BLUE.


Panel / GOR

Practicaly, one production cell can supply a supermarket with multiple references.
It soon becomes difficult to manage priorities, as the different products can have different consumption rates.

To help operator make a decision on next reference, a three zones panel; Green, Orange, Red (GOR).

As long as kanban cards pile up only in the green zone, no problem, inventory in the supermarket is sufficient to supply consumption.

When kanban cards accumulate until they overflow into orange zone, it is a signal that inventory for that reference is nearing shortage. The actual production is to be terminated and changed over to manufacture the required reference. The orange zone is a warning indication of upcoming emergency.

If kanban cards overflow into Red zone, it is mandatory to stop immediately current production and changeover to this reference. The red zone rouge is indication of top emergency. If there is no immediate reaction, customer will suffer shortage.

Practically,

  • GREEN If kanban cards are all in green zones, operator chooses next production.

  • ORANGE If one product reference has its kanban cards overflowing into orange zone, he'll change his production for this reference. Proper adjustment of zones (stocks levels) allows normal delivery.

  • RED If one product reference has its kanban cards overflowing into red zone, this means absolute emergency. Operator has to change immediately to this reference and expedite as soon as a minimum quantity is available.

Read on
 HC online


River analogy in inventory reduction
Push flow - pull flow
 

 

Generaly, supermarket is in operator sight, so he can decide by visual control.  

 

 

 

 

The author, Chris HOHMANN, is Managing Partner in an international consulting firm.

He advises companies on industrial and logistics performance issues.

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