Kanban is a management tool just in time, which allows to work in pull system. This is an important step to reach the one piece flow wich is is the goal we must set ourselves.

This method has advantages as :

  • Rapid implementation that does not require large financial investments
  • Self-managed method
  • Reduced production and delivery time
  • Visual method
  • Motivation operators

 

So why, this tool is not regularly deployed in industries of wood and furniture?

 

There are 3 types of barriers :

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  • The psychological barriers
  • The organizational barriers
  • The technical barriers

 

The psychological barriers :

  • Some think these management methods are only made for leading businesses, and large enterprises. How many times have I heard: But we’re not Toyota – We, we do not have the same problems as other.
  • Some production managers fear losing control of their task. Kanban being a self-managed application method does not require operators. Against the manager is required for the establishment.
  • Senior management and controllers are sometimes reluctant to setting this up, because they believe that the monitoring of cost and budget control will not be possible.

The organizational barriers :

  • The management of a product by Kanban requires regularity of demand for this product. A furniture manufacturer with a range of products (color – size) wide, can not manage facades with Kanban. A joinery which works by order can not manage the wood components and glazing with Kanban.
  • The kanban, can not be applied to components made in small series. So we will have to classify the components according to their consumption.
  • The kanban, requires substantial responsiveness throughout the supply chain. Changeover time time must be low. So you often go through SMED before to implement kanban.
  • Last, although the Kanban is a pull flow management, it is mandatory to have in place an upstream planning and to know what the average consumption of the products concerned.

The technical barriers :

  • In the furniture industry (panels) or the carpentry industry (plaice), an important step in the supply chain is the flow optimization. This step is very important to optimize the material. For against, it may hinder the implementation of kanban, generating different amounts of the batch size.
  • Another barrier is the material: wood is a heterogeneous material, which unfortunately often has flaws that can disrupt an application ‘theoretical’ of kanban.
  • Finally, a habit of the profession greatly disrupts the implementation of kanban and pull flow. This is the storage components on roller tables. This method works perfectly with a management driven flows, but can not operate in pull system. It brings a much too rigid scheduling.

 

Freins

 

 

What products manage with Kanban?

You have decided to implement a pull system management for certain components. First, we have to select pilot references. Kanban works with repetitive manufacturing or supply and relatively stable.

The ideal is to start with the management of certain purchased components (hinges, slides, pins, inserts, screws, …) or products manufactured batch (strips, back, …). The installation is explained in a dedicated chapter.

The hardware (hinges for example) are the ideal product for a pilot start.

  • Process supply assembly lines
  • Using a supermarket, setting up a milkman run
  • Analysis of the volume, consumption, variability
  • Calculating the number of kanban
  • Calculation of the maximum work in process
  • Validation of all – Installation System
  • The deployment of the cycle of continuous improvement

Calculating the number of Kanban and maximum outstanding is performed as follows :

N = ((D + S) x (Q/t)) / C

  • N = Number of kanban
  • D = Deadline for return of a Kanban sent to the warehouse
  • S = Safety delay
  • Q = Daily consumption
  • t = Daily timetable
  • C = Capacity of a container

M = N x C

  • M = Work in process maxi

Consider the following criteria :

  • D = 8 hours (1 milkman run per day – Kanban recovery and delivery to the next tour)
  • S = 2 hours
  • Q = 150 hinges per day
  • t = 8 hours per day
  • C = boxes of 50

N = ((8+2) x (150/8) / 50 = 3.75

N = 4

M = 4 X 50

M = 200

Here is a simple product to start and to train for the implementation of Kanban. You can deploy it on all hardware components with the regular consumption. Then implement Kanban loops on manufactured goods, and for which you have a regular consumption. This will go hand in hand with a continuous improvement process : you must learn to smooth consumption, reduce the setting time for the manufacture, develop self-control to deliver only good parts, …

Kanban will probably be the first tool you will use in your willingness to switch to pulled flow.