Determination of Number of Kanbans

Bhaskara P
I semester PEST
National Institute of Engineering, Mysore-08
Supplying
Process
Assembly
process
part
Production Card
Finished parts
Store
Withdrawal Card
part
Kanban Information system
Kanban (pull) System
Withdraw/Pull only what is needed
Replenish what is withdrawn
Overall Benefits
Prevents overproduction
Reduces inventory
Fig.1. 2 kanban card information system
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Kanban Information system
Fig.2. kanban card
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Process of Kanban sizing
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Determine the daily demand
Calculate No. of kanban cards
or
quantity per kanban
Print Kanban
Withdrawal Systems
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Withdrawal system
Constant quantity,
non constant cycle
Constant cycle,
non constant quantity
Constant cycle system
for supplier kanbans
Used within the plant
Shorter lead time
Improved processes




where,
S = safety co efficient (should not be less than 0.1)
C = container capacity
D = daily demand
lead time (days)= Tprocess+Twaiting+Tconveyance+Tkanban collecting
i). The constant quantity, non-constant cycle
withdrawal system
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=
Avg. D X lead time X (1+ S)
Total No. of kanbans
C
=
economic lot size+ (D X S)
Total No. of kanbans
C
Larger lots
Smaller lots
E.g.: 1. D=100
lead time=0.5 day
C=10
S=0.2

No. of kanban = [100*0.5*(1+0.2)]/10
= 6
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i). The constant quantity, non-constant cycle
withdrawal system.
ii). The constant cycle, non-constant quantity
withdrawal system



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Kanban No. is fixed
Demand doubles then, only kanban circulation doubles
Quicker problem identification
=
D X (order cycle + lead time + safety period)
Total No. of kanbans
C
Used within the plant
Relatively larger lead time (process/conveyance)
= Order quantity No. of kanban detached by regular collection X C
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ii). The constant cycle, non-constant quantity
withdrawal system.
E.g.: 2. D=500
order cycle= 0.2
lead time=0.5
Safety period=0.2
C=40

No. of kanban = [500* (0.2+0.5+0.2)]/40
= 11.25 ~ 12

Order quantity = 3 * 40
= 120

iii). The constant withdrawal cycle system for
Supplier kanbans
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| |
= +
`
|
\ .
)
100 1+ 2
Total No. of kanbans [[1]] * 0.2
5 6
= Total No. of kanbans 14
| |
= +
`
|
\ . )
D 1+ conveyance interval
Total No. of kanbans [[No. of days spent for conveyance]] *
C No. of convey/day
S
Used for Supplier kanbans
geographical distance
longer lead time
slightly varying quantity
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