What is Kanban?

One of the most common tools used in the pull production system is referred to as "Kanban." Although the terms "pull production" and "Kanban" are often used interchangeably, Kanban actually refers specifically to a signal card production system. This system utilizes cards or containers to pull materials or products through the production system. It relies on a simple rule of only producing or delivering when a card or empty container is passed to the workstation.

Main Aspects of Pull Production/Lean Manufacturing

Organizing for Flow - - - (Products, Material-flow, Equipment and Support):

• It is focused on defining products, equipment and material-flows (process orientation) that can be produced in small lot production runs being “pulled" by downstream customer demands.
• It is oriented to getting the product to the customer in the shortest period of time and at the lowest cost with superior quality and customer satisfaction.

Pull Planning (with Visual Control)

The Lean team needs to plan for separation of:

• MRP System function: (Reconciliation – the process of high-level demand planning and scheduling)

from

• Day-to-day planning functions (Regulation – the process of regulating command and control sequences within a pull-process environment capable of controlling “workable work” for each production unit and production cell.
• MRP must also project intermediate and long-range procurement objectives to suppliers.
• The day-to-day and shift-by-shift operations will need a real-time Plant Operations Control (POC) system preferably visual

Organization for Pull

• Pull Production demands a re-thinking of the structure, role and responsibility of each individual within the organization.
• The formation of Production Units operating as “Business Units” & Flat Organization will help to understand the needs of their customers and organize all resources, products and capabilities to support and add value to its customers needs and expectations.
• Team Empowerment is the key to the success of such Pull Organizations

Performance Measures

• Performance Measures must be developed in a hierarchy that is cascaded upward and downward within the organization.
• The measures should be understandable, simple to administer and enable management and team members to easily make decisions and take action when appropriate.

GO TOP

Further Reading on Pull Production/Concept

1. THE DIFFERENCE BETWEEN PUSH AND PULL
2. Push–pull strategy
3. Kanban - Detailed Explanation