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Classroom Logistics
• Introductions
• Facility orientation
– Location of restrooms
– Time Schedules (Breaks)
– Coffee station
– Facilities
• Student Expectations
• Other administrative matters
• Any questions?
Agenda
• KANBAN process
– The KANBAN method for controlling production and material flow is based on the actual stock
quantity in production.
– Material that is required on a regular basis is continually provided in small quantities directly
to the production line.
– Replenishment of the production of a material is only triggered when a higher production level
actually requires the material.
– This replenishment is triggered directly in production using previously maintained master
data.
Kanban Replenishment
Production
Production process
process
Ful
l Replenishment
is triggered
Empty automatically
Supply
Supply • Prod. order
Area
Area Status to EMPTY • Purch. order ...
source
Supply
Production
Production process
l
Ful
Goods receipt
posted
Supply
Supply automatically
Area
Area Status to FULL
Full
Full Kanban
source
Supply
Benefits
1. What is Kanban?
Replenish Materials
Manufacturing
Pick list is
printed daily in Pick List
stock room / A
warehouse
Yes
No
Yes
Backorder
Processing
B
Inventory Control
Define Activities
and Activity Rates
Review
Transfer
A Pick List
Inventory C
Pick
Material
Process
Kanban Control Process Flow (cont’d)
Replenish Materials
Manufacturing
In-house
Does a Is material Is Kanban
control
Yes available in
No Set container
material to be
Yes procurement
B cycle all Kanban
status to
manufactured
proposal is
“Empty” created
exist? containers? in-house?
automatically
No
No
Yes
Remove
Maintain control material from
cycle for
material
containers as C
required
Inventory Control
Replenishment
Transfer or Transfer
signal sent to Transfer
purchase
inventory Inventory D
material?
control
Purchase
Purchasing
Replenishment
Procure
signal sent to
Material D
purchasing
Kanban Control Process Flow (cont’d)
Replenish Materials
Manufacturing
D C
R eceive R emo ve
M an ufacture material F ill K an b an Set con tain ers material fro m
con tain ers co n tainers as En d
Pro d u ct at work statu s to full
center req u ired
Kanban Control Cycles
Empty Full
Kanban Control Cycles
# of
Containers
Demand Quantity of
Source Material
Maximum Supply
Control Cycle
Empty Source
Information
Person Kanban
Responsible Printout
Replenishment
Calculation of the Control Cycle
Number of Containers
~ ~ ~ BASED ON ~ ~ ~
C
o
n
s
u
m
pt
io
n
Time
Supply Areas
Company
Plant
Storage
Location
Responsible
Person
Supply Supply
Area Area
Replenishment Strategies
Control
Cycle
• Summary
• Next Steps
• If you Need Help . . .
• Questions
• Student Validation
• Class Evaluation
Course Summary