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Pull (Kanban) Production

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Pull (Kanban) ProductionWhat is pull production

Product is produced only when the nextoperations needs it. Ideally, dont builduntil the customer has placed an order.

If one piece flow does not exist, a materialreplenishment system is required.

Also known as Supermarket Production

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A Japanese word, means Visual Board

Apply Kanban as a special tool forimplementing pull production, so it isalso names as Kanban Production.

Kan

Visual

Ban

Board

Pull (Kanban) ProductionWhat is Kanban

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Pull (Kanban) ProductionTwo Types of Pull Production (1/2)

Make To Store

Production Lines WarehousePreceding Station

(Process) Following Station(Process) Following Station

(Process) Preceding Station

(Process) Preceding production process keep a minimum inventory offinished parts, and fill-up for those parts withdrawn by followingprocess.

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Pull (Kanban) ProductionTwo Types of Pull Production (2/2)

Make To Order

Production LinesCustomer

Place order

Shipping

(Movable Warehouse)

Production take place after order are received, rather thanbefore

Zero F/G Inventory in warehouse

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Pull (Kanban) ProductionPush Production V.S. Pull Production

(1/2) Customer

Push Production

SupplierMaterial

WarehouseWarehouse

F/G

MachiningLine

Assembly Line

PurchasingOrder

MaterialReceiving

PlanMachining

Plan

Assembly

Plan

Production Control

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Pull (Kanban) ProductionPush Production V.S. Pull Production

(2/2) Pull Production

Supplier

Material

Warehouse

Machining

Line

Assembly Line

AssemblyPlan

Production Control

Customer

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The Kanban serves as to1.) Provide instruction for

production and withdraw

2.) Control the level of inventory

3.) Prevent production shut downfrom materials shortage

4.) Prevent from over - production

5.) Detect irregular processing speeds

6.) Simplify the workload for materials

management

Pull (Kanban) ProductionThe Function of Kanban

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Pull (Kanban) ProductionTwo Basic Types of Kanban

Production Kanban This Kanban is used toorder the start of

production at eachproduction station.

Withdraw Kanban This Kanban indicates

the timing and quantityfor pick up a newsupply of parts from apreceding process todelivery to following

process.

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Pull (Kanban) ProductionBasic Operation Procedure forKanban

Start Production

Finial AssemblyLine

WithdrawKanban

Withdraw

Kanban

ProductionKanban

PartsMachiningCell

Production Kanban + Parts

Withdraw Kanban + Parts

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1) Only allow the following station togo to preceding station to withdrawthe parts by instruction of Withdraw

Kanban

2) The preceding station only canproduce the quantity by theinstruction of Production Kanban

to replenish those quantity whichhad been withdrawn by followingstation

Pull (Kanban) ProductionThe Operation Rule of Kanban (1/2)

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Pull (Kanban) ProductionThe Operation Rule of Kanban (2/2)

3) Without Kanben, can notproducewithdraw the parts

4) All parts should attach with aKanban

5) All parts should be 100% good

6) Try to reduce the number ofKanban for reducing theinventory level

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One Piece Flow ProductionLeveling (Heijunka) Production

Standard Work

Pull (Kanban) ProductionPremises of implementing KanbanProduction

Quick Changeover