Working details of Kanban for production?

Answer 1

First, you have to do is cleaning up your production lines from any access of parts or materials. Then arrange or divide the production line into production cells or production centers, and list up what parts or materials it needed each cell.

Second, determine the speed of production, hourly or daily, it should be constant.

Third, determine the type of pallet to contain for the parts or the material. Manually handled pallet plus the parts should not wight more than 25kgs. Then you are able calculate how many parts are in each pallet.

Fourth, then decide an area divided as the production line divided by cells, to place all the pallets needed respective to the production cells.

Fifth, determine the lead time to provide the replenishment for each parts, in hours, then multiply with production speed per hour, you get the reordering point, Red Line, number of pallets and number of the Cards (Kanban) at reordering point.

Sixth, since you have the daily production speed, you can calculate as in the fifth, and you get quantity of the pallets and quantify of the Cards that will be in the production cell before reordering.

Seventh, now you get the total numbers of the Cards as well as the pallets and make a rack for the Card Hanger.

Eight, then arrange working routine as follows; by the end of working day (supposedly you work one shift) all the production lines are supplied with the parts (in sets) it needed, ready for the next day production.

Appoint a person as Router, to take the empty pallet as well as the card attached to each pallet.

Place the empty pallet in Empty Pallet Area, and hang on the Card Hanger.

Appoint another man as Store Keeper, who is checking the store for Red Line, if he sees one, then he should go to the Card hanger, take the respective Cards, put it on the respective pallets and send it to the Process Before or Supplier.

To keep the Router and Store Keeper awareness, you can install automatic alarm or red light.