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Ways to schedule batch processes with kanban

Part #. Part #. Part #. Part #. Part #. Part #. Part #. Part Description. Location. Date Triggered. Lot Size. Trigger Point. Machine #. Tool #. Ways to schedule batch processes with kanban. 8 hour cycle. Pattern production +Predictable sequence, stability

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Ways to schedule batch processes with kanban

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  1. Part # Part # Part # Part # Part # Part # Part # Part Description Location Date Triggered Lot Size Trigger Point Machine # Tool # Ways to schedule batch processes with kanban 8 hour cycle • Pattern production • +Predictable sequence, stability • -Inflexible to changes during shift P1 P2 P3 P4 P5 P6 Sequence fixed, part time variable • Lot making with batch board • +Visual control, shorter lots possible, info • -Many cards per part #, requires discipline Trigger Point Full Empty • Triangle kanban • +Single kanban to control, pressure to reduce C/O time • -Fixed quantity unfixed time cases only

  2. 2 Emergency Delay OK Sample triangle kanban flow Inventory Signal kanban rail Batch Process C Current Next 3 Part # 15456 1 15456 15455 15454 B Part # 15454 Part # 15455 Note: Only 1 triangle kanban per part # is needed in this flow

  3. Part # Part Description Location Date Triggered Lot Size Trigger Point Tool # Machine # Triangle Kanban

  4. Short exercise - Steps for setting up triangle kanban* • Step 1: Determine time available for changeover work. • Step 2: Set the number of changeovers per day. • Step 3: Establish a lot size for production. • Step 4: Establish a trigger point for reorder. • *Assumes part numbers have already been dedicated to run on certain machines

  5. Step 1: Determine time available for non-production work (1 machine*) *The three part numbers dedicated to this molding machine

  6. Step 2: Set the number of change over events per day

  7. Step 3a: Establish the batch factor Number of part numbers on the machine Batch Factor = Number of C/O’s per day In this molding machine example 3 part numbers = 1 3 C/O’s Lot Size = 1 day of production per part number

  8. Step 3b: Establish the lot size Total 1000 pieces

  9. Step 4: Establish the trigger point for reorder Trigger point = Total lead-time to replenish Part takt time *Inclusive of scrap loss

  10. Step 4: Establish the trigger point for reorder (continued) *Assumes longest run time item at front of queue for the three part numbers. **Rounded to the nearest 10 (box quantity)

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