LEAN MANAGEMENT

Kanban
Submitted by:
Gitika Tayal(BFT/19/79)
Ishika Malu(BFT/19/62)
Prakriti Gorai(BFT/19/75)
CONTENTS
Kanban
Types of Kanban
Why Kanban
Rules of Kanban
Terms related to Kanban
Supermarket
Prerequisite Kanban
Calculation of Kanban card
Information on Kanban Card
Implementation
Functioning
Conclusion
 KANBAN
A N
N B Japanese meaning signal or card
KA
Pull-based visual signals

Allocated for each part being manufactured

Tie the different manufacturing plants together

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 TYPES OF KANBAN

PRODUCTION KANBAN WITHDRAWAL KANBAN

ORDINARY TRIANGULAR INTERPROCESS SUPPLIER

PRODUCTION KANBAN KANBAN KANBAN
KANBAN

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ACHIEVE

Why
To achieve smaller lot sizes and huge inventory
reductions.

AUTHORISE

Kanban
To authorise the upstream process to produce
only when there is a requirement for production.

ELIMINATE
To eliminate losses occurring due to
overproduction.

REDUCE
To reduce costs by minimizing the W.I.P. inventory

ADAPT
It allows an organization to adapt to changes in
demand, and therefore production is quick.

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 WHY KANBAN IN MESSRS SUN GARMENT
INDUSTRY IN BANGALORE

The fabric rolls move from the

stores department and undergo
various operations

Accordingly data was collected for

each department

The company follows the push

system

hold of huge amount of work-in

process at every stage of the
Work in process at every stage (existing practice)
material flow

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 RULE 1: ATTACH

RULES
RULE 2: FULL AUTHORISATION

RULE 3: REJECT

RULE 4: MINIMIZE

RULE 5: ADAPT

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 Terms Related To Kanban
ONE CARD TWO CARD TWO-BIN SYSTEM
SYSTEM SYSTEM
Two bins have the stocks
A single card is used to Two cards are used One is in the production
replenish stock when it is one for Production Other to be used next
at its defined minimum and one for while order is placed for
withdrawal materials to fill the first
bin.

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 Supermarket
SUPERMARKET

The location where a predefined amount of inventory is

controlled
Conditions for a
Supermarket are:
logically designed and installed facilities Products are organised as
per their types
Backbone of pull system FIFO is maintained
Triggering the demand to
bridge between the consuming process and the supplier
replenish and reproduce

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 PRELIMINARY ACTIVITIES
TO IMPLEMENT KANBAN

Creating a Kanban sizing report

Cycle counting, part identification, vendors and on-hand inventory

identification of inventory quantities

Calculating the on-hand cost of new inventory

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 CALCULATION OF KANBAN
CARDS
This calculation directly affects the inventory levels as well as the replenishment cycles
suggested by a Kanban equation to determine the number of Kanban required.

Number of Kanban = Average daily demand x (order frequency + lead time + safety
time)/Container quantity

For Messrs Sun Industry

Number of Kanban cards required = 10

Hence, five withdrawals and five production order Kanban were designed.
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Card serial number
Item number/item code Information on
Kanban Card
Item name
Quantity
Unit WITHDRAWAL KANBAN
CARD
Item image
Packaging type part number
Customer information part name
Supplier information lot size WI TH DR AW AL KA NB AN
Supermarket detail routing process CA RD
Other information name of the next process
materials required as inputs
location of the next process
at the preceding stage
name of the preceding process parts required as inputs at
Location of preceding process the preceding stage
container type information stated on
container capacity withdrawals Kan-ban
number of containers released

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Kanban Identification card

Kanban Board for sewing section

Step 4 Step 1

How do we
Implement?

Step 3 Step 2
 Functioning Of Kanban
Kanban board

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HOW TO IMPLEMENT IN MESSRS SUN
GARMENT INDUSTRY IN BANGALORE

Work in process at every stage using Kanban

cards

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 CHANGES IN MESSRS SUN GARMENT
INDUSTRY IN BANGALORE - RESULT

reduce in inventory,

minimum damage to the materials,

higher clarity in the material flow

Wellstream lined Production

Comparison between existing system and kanban

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REFERENCES
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cbl=18750&diss=y&pq-origsite=gscholar
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Seboka/publication/348324783_PROCEEDING_CTA-
2019/links/5ff7f36c299bf140887d89f8/[Link]#page=150
[Link]
Kanban_the_new_generation_of_traditional_Kanban_system_and_the_impact_of
_its_implementation_in_the_enterprise
[Link]
uXLhDwAAQBAJ?kptab=getbook&gbpv=1
[Link]
cairo/documents/publication/wcms_621950.pdf
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Thank you