Kanban Control
Two-bin kanbans
WIP kanbans
Kanban levels
Resources to support Kanban
Backflushing When to do it How to do it Setting up routings When it doesn’t work
From his experience in implementing Lean systems in various manufacturing environments, and his observations of Lean manufacturing environments, and discussions with the people involved, there are basic lean caveats that have to be in place.
• Lean is a methodology and a state of mind. It is also a commitment to a set of manufacturing practices. To implement some kanbans on the shop floor and institute a form of back-flushing does not, in itself, constitute Lean. In fact kanbans and back-flushing can create more problems than they seek to solve, thus a complete understanding of the controls and procedures necessary is needed to use these tools efficiently.
• However, aspects of Lean can be used by a company wishing to take advantage of some Lean Manufacturing concepts without going “whole hog” with the resource commitment that that would entail. Using the “8 wastes” that Lean attempts to reduce is a good place to start.
• There are certain environments in which Lean works much better; Make to Stock and Assemble to Stock lend themselves more to Lean than a heavily customized Make to Order environment does. So companies implementing Lean have to be very careful how they approach it.
Body of knowledge / Best Manufacturing Practices
The major reason that ERP systems fail or do not give the results expected or hoped for is that the inputs to the system are not correct or accurate. An obvious example would be trying to utilize an MRP system with BOM’s that are not accurate or Planning data (lead times, safety stock, order quantities etc.) is not correct.
8 Wastes that Lean attempts to mitigate
• Over-production (batch sizes more than needed)
• Waiting (waste of time)
• Over-processing (doing more than is needed)
• Excess inventory and Work in Progress
• Motion (unnecessary movement in producing the part)
• Transport (movement of material in making the product)
• Defects (waste of material)
• Unused people skills
