8/11/2019 Kanban Design

1/1

Once we developed the Kanban design. We are ready to calculate the size of the kanban based on the collected data.

The method used to calculate the size of the kanban based on current existing production schedule. The calculation

of kanban is to determine the optimum number of kanban card in the system.

Toyota formula was used to determine the number of kanban

( )(1 )D T P b

QK

......... (1)

Where, K is number of kanban card, D is average daily demand for the month, T is Waiting time ,P is Processing

time, b is policy variable(10% of daily demand) ,Q is container capacity

From the above Toyota equation (1) we drive the formula for the single card kanban system,

(1 )D b

QK

. (2)

Where K is number of kanban card, D is average daily demand, b is policy variable (10% of daily demand), and Q is

container capacity.

From the equation (2) we find the optimum number of card for the each process of diaphragm.

5.4 Implement Kanban systemAfter designed the kanban system and calculated kanban size the implement can be start. Before implement we need

to we need to train everyone in the organisation on how the system will work and on their role in the process.

Developed a simple presentation to explain the process, visual signals and review the rules during the training.

Finally, during the deployment stage, develop transition plan determined the exact process for the change and the

amount of inventory required to make the change. We need to confirm the design is implemented, confirm training

is completed, and check the inventories ensure a successful implementation.

After the kanban started, next step of the successful implementation process auditing the kanban. The first step to

the auditing process is to set up a regular schedule for conducting the audits. We recommend making this a daily

procedure initially, and later reducing it to once or twice per week. The audit process consists of cycle counting and

reviewing past production records. The cycle count will provide an up-to-the-minute inventory that can be compared

to the signals to make sure they match. The review of production records will confirm that the production operatorsare following the kanban signals. To determine whether the kanban size supports production requirements, compare

the current production requirements forecast to the baseline quantities used to size the kanban. If the requirements

have changed by 15 to 20 percent, then consider resizing the kanban. The audit will take the physical form of

conducting a cycle count, counting the signals, direct interaction with the operators, material handlers, customers

and their supervisors, checking the kanban design and size versus the long-term requirements. Each process auditing

is noted and record it for further changes.