Kanban for the Shopfloor : The Productivity Press Development Team

Publisher's Message ix Getting Started xi The Purpose of This Book xi The Basis of This Book xi Two Ways to Use This Book xii How to Get the Most Out of Your Reading xii An Overview of the Contents xiv Introducing Key Terms and Benefits of Kanban 1(10) What Is Kanban? 2(2) The Pull System and Waste Reduction 2(2) What Will Make Kanban Successful? 4(2) Integrating Kanban with MRPII 5(1) Pilot or Plantwide Implementation 5(1) How Will Kanban Change What You Are Doing Now? 6(1) What Are the Benefits of Kanban? 7(2) Kanban and Your Company 7(1) Kanban and You 8(1) In Conclusion 9(2) Summary 9(1) Reflections 10(1) The Basics of Kanban: Functions, Rules, and Types of Kanban 11(18) The Differences Between Kanban and Conventional Ordering Systems 12(5) Reordering Point Method and Kanban 12(1) Production Work Orders and Kanban 13(1) MRP II 14(1) A Summary of Push versus Pull 15(2) Functions of Kanban 17(1) To Serve as the Autonomic Nervous System for Just-in-Time Production 17(1) To Improve and Strengthen the Factory 17(1) Rules of Kanban 18(3) Rule 1: Downstream Processes Withdraw Items from Upstream Processes 19(1) Rule 2: Upstream Processes Produce Only What Has Been Withdrawn 19(1) Rule 3: Only 100 Percent Defect-Free Products Are Sent to the Next Process 19(1) Rule 4: Level Production Must Be Established 20(1) Rule 5: Kanbans Always Accompany the Parts Themselves 20(1) Rule 6: The Number of Kanbans Is Decreased Gradually Over Time 20(1) Types of Kanban 21(5) Transport Kanbans 21(2) Production Kanbans 23(3) In Conclusion 26(3) Summary 26(1) Reflections 27(2) Phase One: Scheduling Kanban 29(22) How Many Kanbans Do You Need? 30(2) Takt Time 32(1) How Many Operators Are Needed? 33(9) Line Balancing 33(3) Full Work 36(6) Load Leveling or Smoothing-Heijunka 42(5) Level Production Compared to Shish-Kabob Production 43(4) In Conclusion 47(4) Summary 47(2) Reflections 49(2) Phase Two: Circulating Kanban 51(16) When Do You Produce? 52(2) What Do You Replenish? 53(1) When Do You Pull? 54(1) Where Can You Pull From? 54(1) What Do You Pull? 55(1) What Belongs on a Kanban Card? 55(1) How Do You Attach Kanban Cards? 56(1) Steps for Circulating Kanbans 56(8) Rules for Circulating Kanbans 58(1) Rules for Transport with Kanbans 58(1) Supermarkets 59(2) Water Beetles and Milk Runs 61(3) In Conclusion 64(3) Summary 64(1) Reflections 65(2) Phase Three: Improving with Kanban 67(22) Fine-Tuning Production by Reducing Kanbans 68(4) Kanban Highlights Abnormalities 68(1) Reducing Kanbans Reduces Stock 69(3) Kanban As a Visual Control System 72(10) What Is the Essence of Control? 73(1) Five Important Steps in Creating Visual Controls 73(2) Triangle Kanban 75(4) Other Types of Kanbans 79(3) Kanban and Suppliers 82(3) In Conclusion 85(4) Summary 85(2) Reflections 87(2) Reflections and Conclusions 89(7) A Kanban Implementation Summary 90(2) Reflecting on What You've Learned 92(1) Opportunities for Further Learning 92(1) Conclusions 92(1) Additional Resources Related to Kanban 93(3) Books and Videos 93(2) Newsletters 95 Training and Consulting 55(40) Website 95(1) About the Productivity Press Development Team 96