KanbanOne of the simple tools used in lean manufacturing is the kanban. This is a communication tool used in the manufacturing process. Simplest form of kanban can be used as a visual indication of the requirement in upstream. Kanban system goes in together with the pull manufacturing system. Pull manufacturing is the basic lean manufacturing concept which makes the system flexible and easy to use. Kanban cards are used to display the requirements of the production unit to the production facility or the warehouse immediately before it. When this signal is received the process below will work to fill the requirement created by the process upstream. In the simple form this communication process will take care of the internal manufacturing activities. But in more complex systems kanban techniques are used in signaling the suppliers and other outside parties about the requirement of the manufacturing facility. This is the ultimate aim of lean manufacturing, which will group the customers and suppliers with the manufacturing facilities. Advantages like lower lead times, low costs and floor space savings are directly resulted with this technique. It is not complicated to understand the kanban concept if you take a supermarket as an example. When goods are purchased by the customer there will be a reduction of the stock in the rack cells. These rack cells have a fixed volume. When there is a reduction to the stock it provides visual signal to the Clerk who is assigned to the task of refilling the cells. Then the main warehouse will be informed about this requirement. The exact requirement will be refilled daily or twice a day as required. In the modern setup this triggering part will be done in the issue counter and signals will be electronically delivered to the warehouse so that they will know the requirement virtually online. Some say this is the easiest concept of lean manufacturing which can be used anywhere without major difficulties. But the reality is kanban alone can do very little to your organization. It should be used with correct understanding of lean manufacturing. Remember lean manufacturing principle is all about seeing the bigger picture. Kanban is not an exception to this basic lean principle. |
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