10 Kanban_Card_Calculation (1)

10 Kanban_Card_Calculation (1) - Kanban Card Calculations 1...

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Kanban Card Calculations Kanban Card Calculations
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1. 1. Production Kanban Production Kanban PROCESS 4 …… …… …… …… Process Initial Buffer Process Final Buffer 3 2 1 5 Kanban Receiving Post Kanban Ordering Post : Material Flow ……. : Production Kanban Flow 6
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1. 1. Production Kanban Production Kanban Parts consumed during one kanban cycle = Average demand x kanban cycle time Since the demand is not constant, a safety coefficient ( ) is introduced to the above formula Parts consumed during one kanban cycle = Average demand x (1+ ) x kanban cycle time As a rule-of-thumb, should be kept less than 10 percent and should be decreased as the demand becomes more leveled. container per parts of Number cycle kanban one during consumed Parts kanbans of Number container per parts of Number ) (1 x demand Average kanbans of Number time cycle kanban x
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1. 1. Production Kanban Production Kanban The kanban cycle time is the time spent by a kanban to complete a full cycle; it involves six distinct phases as numbered in the figure above. They are: 1 . The production kanban is removed from the full container when the container is withdrawn from the final buffer for transfer to a downstream process; the kanban is then placed in the kanban receiving post and waits there until collection. 2. The kanban is transferred from the kanban receiving post to the kanban ordering post at the initial workstation. 3. The kanban waits at the production ordering post behind the other production kanbans (FIFO). 4. The kanban is taken from the production ordering post and attached to an empty container, the process machine are set up, the quantity of parts to process (equal to the container size) that was indicated on the kanban are withdrawn from theinitial buffer; the parts are then processed and placed in the container upon completion. 5. The full container (with its kanban) is transferred to the final buffer. 6. The container waits until withdrawn by downstream process (the cycle is then complete).
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1. 1. Production Kanban Production Kanban Kanban cycle time = kanban waiting time in receiving post + kanban transfer time to ordering post + kanban waiting time in ordering post + lot processing time (internal setup + run time + in process waiting time) + container transfer time to final buffer + container waiting time in final buffer.
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1. 1. Production Kanban Production Kanban Example: Average demand = 100 parts/hour, Container size = 100 parts, Kanban waiting time in receiving post = 5 min., Kanban transfer time to ordering post = 1 min., Kanban waiting time in ordering post = 30 min., Maximum internal setup time = 5 min., Maximum processing time = 0.25 min/part, In-process waiting time = 10 min., Container transfer time to final buffer = 5 min., Container waiting time in final buffer = 10 min., Initial safety coefficient: = 0%.
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1.
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