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KanbanKanban takes different forms:Cards Empty Containers Empty Dollies Electronic Signals Electronic Kanban Production Pull(Bill Of Material)Timed Deliveries KanbanElectronic Kanban Electronic KanbanDefinition Electronic Kanban:The baseline is still the Kanban card.On the Kanban card you find one or more Barcodes and on each box you find one of these Kanban cards.If the material of one box is used in the production and if the box is empty,the operator uses his Barcode-reading machine to tell the system this box is“empty”.With this information the production of this part or the external demand starts and the empty box will be replaced.Electronic KanbanA-108How it works:Electronic Kanban-BremenFull containerFull containerConsumption in the assemblyConsumption in the assemblyEmpty containerEmpty containerAcquisition with ScannerAcquisition with ScannerData transfer to the supplierData transfer to the supplierExteral SupplierInventory Level Information to the supplierIvoices for LearElectronic KanbanElectronic Kanban with external suppliers:With the help of a planning table it can be visually displayed,how many full and how many empty Kanban boxes for the relevant product are in circulation.Is the electronic Kanban proceeded also with external suppliers,instead of an internal order an external order is produced when the information“box empty”is scanned by the operator.The order is transmitted to the supplier automatically.If the material is delivered,the barcode is scanned again and the box is recognized in the system as“full”.Thereby the material receipt takes place automatically.DCI(warehouse organization program)system implementation in Lear Corp.Poland IIIFirst phase:Barcodes in raw material warehouseStart:September 2003 Electronic Kanban Tychy IIBarcodes in raw material warehousesstart-19.04.2004 Barcodes for ready made productsimplementation:January 2005Project phasesElectronic Kanban Tychy IIWhat Tychy II expect through barcodes implementation:Decrease of material stock and improve its management Increase of material turnover with the same warehouse spaceCurrent registration of incoming materialFull information about material position in the warehouseQuick and simple access to the dataMistake elimination during implement data into the system Reduction of mistakes done by peopleDocuments standardizationInventory differences decreaseRestrict and keep of FIFO rulesQuality rules controlElectronic Kanban Tychy IIQuality controlDeliveryQuality holdKJDPut awayProductionPut awayShipmentReplenishmentLogistics processesElectronic Kanban Tychy IIDCI hardware systemElectronic Kanban Tychy IIData baseWarehousePackage identificationProductQuantityQuality statusWarehouse positionNow we have full information about material!Electronic Kanban Tychy IIMain steps of material flow in DCI:Gate registration Receipt on the warehouse and address of the package Address system on the production Replenishment system for the production FIFO control Quality control See next pagesElectronic Kanban Tychy II Gate registration systemImmediate information about the deliveryElectronic Kanban Tychy IIAddress system in the warehouseFree space usageEach package has own address on the warehouseElectronic Kanban Tychy IIAddress system on the production Production warehouseComponent addressPart number is connect to the place of component usageElectronic Kanban Tychy IIReplenishment systemOrder of missing partsIssue of right componentsPrint of Pick SlipWe scan canban labels on the production to order right components from the warehouseElectronic Kanban Tychy IIFIFO controlKeep FIFO!System aware us when we want to issue on the production“younger”package.Electronic Kanban Tychy IIGate registrationAddress of the packagePackage labelOrder of the componentsProduction orderIssue on the productionElectronic Kanban Tychy IIElectronic KanbanWhy Electronic Kanban:The control and planning in manufacturing companies takes place very often with data processing integrated production-and planning system.Advantage of this system is a high integration of all data from Finance,Logistic,Production up to HR.If there is a Kanban system not integrated in this data processing system,the inventory management of this Kanban products has to be done manually.This is not the case if you are working with electronic Kanban.Then all necessary information are directly scanned into the data processing system.Pros and Cons:Pros:-High integration of all data in the system-Ensures FIFO-Makes the process easier when the supplier is far awayCons:-Expensive System-High complexity Electronic KanbanKanbanKanban takes different forms:Cards Empty Containers Empty Dollies Electronic Signals Electronic Kanban Production Pull(Bill Of Material)Timed Deliveries
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