Following in the footsteps of its popular predecessor, the second edition of this workbook explains how to apply kanban replenishment systems to improve material flow. Kanban for the Supply Chain: Fundamental Practices for Manufacturing Management, Second Edition provides readers with a detailed roadmap for achieving a successful and sustainable kanban implementation. Detailing the steps required for each stage of the manufacturing and supply chain management process, this updated edition focuses on creating an environment for success. It addresses internal mechanisms, including leveling production schedules, as well as external elements, such as conducting a thorough analysis of customer demand. Numerous techniques are presented for setting up kanban that consider a wide array of material types, dimensions, and storage media. This edition presents a wealth of new tools and techniques useful across the broad spectrum of manufacturing environments, including: A statistical data cleansing technique to remove questionable or irrelevant data from kanban calculations Correlation analysis based on simple Excel techniques to guide the decisions around which part numbers "qualify" for kanban An alternative "stair-step analysis" approach for those who are unable to generate correlation data and prefer to use more readily available monthly demand history An approach to analyze supplier performance data vs. lead time and lot size expectations, with risk mitigation strategies for poor performing suppliers This book is for those who are ready to stop thinking about a conversion from materials requirements planning push techniques to kanban pull techniques and want to make it happen now. Stephen Cimorelli provides actionable advice for installing fundamental kanban concepts that can immediately help you increase manufacturing productivity and profitability. The book includes team-based exercises that reinforce key principles as well as a CD with helpful outlines, charts, figures, and diagrams.

Kanban is an approach to provide an effective relation between different components of a Supply Chain System, such as suppliers, manufacturers, warehouses, distribution centers, retailers and finally customers. Instead of pushing parts, in kanban system each proceeding plant(s) sends a signal to the preceding plant(s) for needed parts to be sent. The plants only produce and deliver desired parts when they receive a signal. Number of kanbans can significantly influence the load balance between processes and the amount of orders suppliers need to obtain from subcontractors. A large kanban size results in large amount of work-in-process(WIP) at each workstation. Although, reducing kanban size serves a decrease in WIP, it leads to transportation increase as well as system throughput rate reduction. In this study a multi-echelon supply chain system is considered. Since the model used in this study is mixed integer non-linear programming and solving by exact algorithms such as branch and bound takes lots of time specially when the scale increases, a heuristic method via Genetic Algorithm(GA) is presented and some problems are solved using the proposed GA to illustrate its performance.

Design and Implement a World-Class Replenishment System, Custom-Made to Meet the Needs of Your Organization! In Custom Kanban: Designing the System to Meet the Needs of Your Environment, Raymond Louis helps you to develop and implement a correct and successful kanban system by selecting appropriate kanban techniques based on the specific environmental factors and needs of your company.

Toyota's world-renowned success proves that just-in-time (JIT) makes other manufacturing practices obsolete. This simple but powerful book is based on the seminars given by Taiichi Ohno and other senior production staff to introduce Toyota's own supplier companies to JIT. It teaches the philosophy and implementation of what many call the most efficient production system in the world. Provides a clear structure for an introductory JIT training program. Explains every aspect of the JIT system, including how to set it up and how to refine it once it's in place. Shows how to use a simple visual system to control the production process. Every day more American companies are learning that JIT works outside Japan. Now you can get started with this step-by-step book which guides you through the implementation process. Every engineer, manager, supervisor, and worker should read this book to get the clearest, simplest, and most complete introduction to JIT available in English. Results at American companies after reading this book: Lead-time on one product was reduced from 12 weeks to 4 days. Setup time on a large blanking press was reduced from eight hours to one minute and four seconds. Work-in-process has been reduced 50 percent plant-wide. Factory floor space was opened up 30 to 40 percent in every on of their plants.

This research concentrates on the inventory management decisions within an assembly-type supply chain. The need for this type of investigation is warranted by the fact that intense competition and heightening demand from customers have forced businesses to focus their attention on strengthening their supply chains. The problem is that in any supply chain, there are many factors involved that cause variations and instability within the system. Previous literature indicates that the manipulation of a Kanban system in today's uncertain environment generates unfavorable results. Consequently, the goal is to find a Kanban methodology that would produce robust and consistent results even when the supply chain system is subject to an unstable environment. This research proposes and applies a methodology, based on Taguchi's robust design concept that allows for the implementation of Kanban systems in uncertain environments. A simulation-programming tool, along with Visual Basic, is used to show how this methodology can be used to develop a robust Kanban system under variations in the supply chain environment. A comparison is made between models using a flexible Kanban system design methodology and a robust Kanban system methodology to prove the superiority of the robust Kanban technique in an unstable supply chain environment. This investigation would allow today's managers to have an opportunity to compare different methods of Kanban system design in order to make the most informed choice in this area. From a managerial perspective, this procedure can be used not only for the improvement of Kanban system design for the supply chain, but also to identify important factors within the supply chain for improvement.

Kanban is the name given to the inventory control card used in a pull system. The primary benefit of kanban is to reduce overproduction, the worst of the seven deadly wastes. A true kanban system produces exactly what is ordered, when it is ordered, and in the quantities ordered. It is essentially a dynamic work order that moves with the material. Each kanban identifies the part or subassembly unit and indicates where each one came from and where each is going. Used this way, kanban acts as a system of information that integrates your plant, connects all processes one to another, and connects the entire value stream to customer demand. Kanban for the Shopfloor provides a working manual for those seeking to implement this method of production control in any operation. It defines the various terms and methods employed in kanbans, and illustrates how when adhered to, kanban is an element of continuous improvement that ultimately leads to the ideal of one-piece flow." In addition to reducing the waste of overproduction, kanban will help your company increase flexibility to respond to customer demand, coordinate production of small lots and wide product variety, and simplify the procurement process. About the Shopfloor Series: Put proven improvement tools in the hands of your entire workforce! Progressive shopfloor improvement techniques are imperative for manufacturers who want to stay competitive and to achieve world class excellence. And it's the comprehensive education of all shopfloor workers that ensures full participation and success when implementing new programs. The Shopfloor Series books make practical information accessible to everyone by presenting major concepts and tools in simple, clear language and at a reading level that has been adjusted for operators by skilled instructional designers. One main idea is presented every two to four pages so that the book can be picked up and put down easily. Each chapter begins with an overview and ends with a summary section. Helpful illustrations are used throughout. Other topics in the Shopfloor Series: Kanban, 5S, Quick Changeover, Mistake-Proofing, Just-in-Time, TPM, Cellular Manufacturing