In this slides you will see how really works a Kanban System between a point of use and a supplier. You will see what you need and how the materials and the informations have to flow. Finally, there are some considerations on the most important points to take in account.

1. How it works the Kanban ?
The definitive slideshow to understand how it works the
Kanban Method
Example 1 – Point of Use / Warehouse

2. What you need prior to start ? (therotical aspects)

Why Use Kanban ?

Theory of Kanban

How to calculate the right number of Kanban
Visit
www.leanlab.name

3. What you need prior to start ?

Define the Point of Use

A place to put Kanban

The right number of Kanban

A runner/collector of Kanban

4. Real Example

A point of use (POU) needs balls in 6 pcs / boxes

Consumption is 18 balls / day

The runner pass every day at 10:00 am

The Lead Time to recieve from warehouse = 2 days

Safety Stock fixed at 20%

This means => 8 Kanban Cards in WIP

5. Monday 8:00 AM – Start Work
POU
Warehouse

6. Monday 8:00 AM – Start Work
POU
Warehouse
Kanban Container
is Empty

7. Monday 8:15 AM
POU
Warehouse

8. Monday 8:15 AM
POU
Warehouse
First box of balls
is open for use

9. Monday 8:17 AM
POU
Warehouse
First box of balls
Is open for use
Kanban is located
in the collection
point

10. Monday 9:00 AM
POU
Warehouse

11. Monday 10:00 AM
POU
Warehouse

12. Monday 10:00 AM
POU
Warehouse
The collector
arrives

13. Monday 10:15 AM
POU
Warehouse
Bring the Kanban
to the Warehouse

14. Monday 11:00 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

15. Monday 11:01 AM
POU
Warehouse
1st
box is
finished
In Process –
Recieved Monday
at 10.15 AM

16. Monday 11:05 AM
POU
Warehouse
2nd box is
opened
Kanban
moved
In Process –
Recieved Monday
at 10.15 AM

17. Monday 12:00 PM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

18. Monday 12:00 PM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

19. Monday 14:00 PM
POU
Warehouse
2nd box is
finished
In Process –
Recieved Monday
at 10.15 AM

20. Monday 14:00 PM
POU
Warehouse
3rd box is
opened
Kanban
Moved
In Process –
Recieved Monday
at 10.15 AM

21. Monday 14:15 PM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

22. Monday 17:00 PM – End of Work
POU
Warehouse
3rd box is
finished
In Process –
Recieved Monday
at 10.15 AM

23. Tueday 8:00 AM – Start Work
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

24. Tuesday 8:15 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

25. Tuesday 9:00 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

26. Tuesday 10:00 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM
The collector
arrives

27. Tuesday 10:15 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM
Bring Kanban to
Warehouse

28. Tuesday 10:30 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

29. Tuesday 17:00 PM – End of Work
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

30. Wednesday 8:00 AM – Start of Work
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

31. Wednesday 8:15 AM
POU
Warehouse
In Process –
Recieved Monday
at 10.15 AM

32. Wednesday 8:30 AM
POU
Warehouse
Stick Kanban on
the box

33. Wednesday 8:45 AM
POU
Warehouse
In Process –
Recieved
Tuesday at 10.15
AM

34. Wednesday 9:30 AM
POU
Warehouse
In Process –
Recieved
Tuesday at 10.15
AM

35. Wednesday 10:00 AM
POU
Warehouse
In Process –
Recieved
Tuesday at 10.15
AM
The collector
arrives

36. Wednesday 10:15 AM
POU
Warehouse
In Process –
Recieved
Tuesday at 10.15
AM
Bring Kanban to
the Warehouse

37. Wednesday 17:00 PM – End of Work
POU
Warehouse
In Process –
Recieved
Tuesday at 10.15
AM
Empty in the POU –
a warning to
warehouse is given

38. Wednesday 17:00 PM – End of Work
POU
Warehouse
In Process –
Recieved
Tuesday at 10.15
AM
EMPTY is always a
Visual Warning

39. Thursday 8:00 AM – Start of Work
POU
Warehouse
Because of warning
the material in in POU
at 8:00 AM

40. Thursday 8:15 AM
POU
Warehouse

41. Thursday 8:30 AM
POU
Warehouse

42. Thursday 10:00 AM
POU
Warehouse
The collector
arrives

43. Thursday 17:00 PM – End of Work
POU
Warehouse

44. Friday 8:00 AM – Start of Work
POU
Warehouse

45. Friday 17:00 PM – End of Work
POU
Warehouse
Next Week the same cycle ...

46. Some Considerations

The WIP is under control (48 balls in 8 boxes)

Is the system too risky of stock-out in the POU and why?
Looking carefully at the lead time, if the collector comes
at 10.00 AM, the POU start at 8.00 AM and the
warehouse brings the boxes at 9.00 AM the lead time to
consider is not 2 days but 2 days and 3 hours.
In this case the correct lead time to use is round 2.5 days
and the kanban system need is:
9 Kanban Cards rather than 8 Kanban Cards

47. Some Considerations

At the beginning of Kanban Implemetation starts with a
safe number of kanban cards and then reduced it when
the system will be stable and reliable.

48. Thank you for your attention
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www.leanlab.name
Info.leanlab@gmail.com