Course Outline:

This course covers how to design and implement a visual material replenishment system that links with your information system.  Emphasis is also placed on lot size reduction and effective capacity utilization as an enabler of kanban systems.

The training will be “teach & do”, a combination of lecture, exercises, and discussions on how to use kanban to implement a pull system.  The content will be:

• Lean Manufacturing, pull systems & kanban
• Kanban: broad definition
• Kanban: narrow definition
• The types of kanban
• When to use kanban
• The four functions of kanban
• Prerequisites for kanban
• Kanban quantity calculation
• Kanban circulation
• Time-fixed and quantity-fixed systems
• Sizing and locating supermarkets within your Value Stream
• Water Spider routes and frequencies to support kanban
• Using heijunka tools for load leveling
• Lot size, Quick Changeover & kanban
• Continuous improvement with kanban
• Maintaining a kanban system

Learning Objectives:

At the successful completion of this course, the participant will be able to

• Define kanban correctly
• Explain the types of kanban and when they are used 
• Calculate kanban quantities
• Describe the steps in circulating kanban
• Give a simple demonstration of how withdrawal and production kanbans work
• Describe the relationship between kanban, heijunka, cycle time and takt time
• Explain the purpose of kanban, responding to the demand with the smallest possible muda (waste)

Benefits:

This course will allow you to take steps to implement a kanban system, and a successful kanban system will result in:

• Appropriate inventory levels
• A simplified material flow
• Less labor-intensive production execution system
• A visual management system for inventory
• Faster and more accurate flow of information through your processes
• Limiting or eliminating overproduction
• Improved on-time delivery

Who Should Attend:

This course is designed to provide knowledge and practical tools to improve factory operations and advance your Lean manufacturing efforts. People whose roles and responsibilities include the supervision or daily activities of production control, materials management, purchasing, manufacturing operations, scheduling, inventory control, as well as value stream managers or Lean / process improvement specialists should attend.

Duration:

1 day