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The Art of Kanban Streamlining your business The Art of Kanban | creativesafety

The Art of Kanban Streamlining your business The Art of Kanban | creativesafetysupply.com Creative Safety Supply is a global supplier of Safety and Lean products and manufacturer of leading brands such as LabelTac® Label & Sign Printers and SafetyTac® Industrial Floor Tapes. Additionally, Creative Safety Supply offers a wide selection of floor signs, wall signs and other high visibility signage solutions. CSS also bridges the gap between products and knowledge, offering a range of free resources for safety professionals or employees looking to learn more about Safety, Lean Manufacturing, GHS, Continuous Improvement and other topics. or call us at 1-866-777-1360 creativesafetysupply.com Hundreds of Innovative Products and Solutions Knowledgeable Staff Free, Fast Shipping on Orders to US & Canada *some restrictions apply, see website Free Guides, Podcasts, Infographics, Blogs and much more 1. Introduction . . . . . . . . . . . 4 2. The Origins of Kanban . . . . . . 5 3. Benefits of Kanban . . . . . . . 6 4. Reductions in Waste and Inventory . . . . . . . . . . . . . 7 5. Flexibility . . . . . . . . . . . . . 8 6. Cutting Costs . . . . . . . . . . . 9 7. The Art of Kaizen . . . . . . . . 10 8. What Are the Five S’s . . . . . . 11 9. Integrating Kanban . . . . . . . 14 10. Conclusion . . . . . . . . . . . 16 11. Additional Resources . . . . . 17 CHAPTERS The Art of Kanban | creativesafetysupply.com All contents copyright © 2015 by Creative Safety Supply. All rights reserved. No part of this document or accompanying files may be reproduced or transmitted in any form, electronic or otherwise, by any means without the prior written permission of the publisher. This ebook is presented to you for informational purposes only and is not a substitution for any professional advice. The contents herein are based on the views and opinions of the author and all associated contributors. While every effort has been made by the author and all associated contributors to present accurate and up- to-date information within this document, it is apparent technologies rapidly change. Therefore, the author and all associated contributors reserve the right to update the contents and information provided herein as these changes progress. The author and/or all associated contributors take no responsibility for any errors or omissions if such discrepancies exist within this document. The author and all other contributors accept no responsibility for any consequential actions taken, whether monetary, legal, or otherwise, by any and all readers of the materials provided. It is the readers sole responsibility to seek professional advice before taking any action on their part. Readers’ results will vary based on their skill level and individual perception of the contents herein, and thus no guarantees, monetarily or otherwise, can be made accurately. Therefore, no guarantees are made. LEGAL DISCLAIMER The Art of Kanban | creativesafetysupply.com 4 Introduction You might not be familiar with the word kanban, but you are probably familiar with the process. Many businesses and homes already use an organizational system that is loosely based on kanban without even knowing it. Simply put, kanban is an organizational system. The point of this, and really any organizing system, is to keep products stocked and running in an even manner. Kanban is a way of providing signals so that the process of maintaining inventory is simplified. The word kanban comes from Japanese and means billboard or signboard. This word is used because kanban relies heavily on cards that are used as markers for moving and replacing inventory. The whole system centers around these visual cues that help you maintain inventory at the proper levels so that you never keep too much or too little of your products or materials in stock. Most kanban systems rely on cards and bins. The system is a simple act of placing bins on the floor of your factory, one in the store, and one with the supplier. When these bins are empty, employees see a card that has all of the details about the product on it: the kanban card. When the factory bin is empty, it can be easily sent to the store for more of the product, along with its kanban card. The same process then happens at the store. As the store’s bins are emptied, they go to the supplier to be refilled. This system helps materials and products flow through your processes smoothly, reducing wasted time and materials. The Art of Kanban | creativesafetysupply.com 5 The Origins of Kanban The world-renowned carmaker Toyota began studying supermarkets in the 1940s. Supermarkets have a unique in-store system that uses in-store stocking techniques. Their system always provides for adequate amounts of products on the shelves without having to store excess amounts because customers know they can always return to the store for more. Toyota believed that this same process could be applied to the factory floor. The demand for the product guided the ordering of products and their placement on the shelves. In 1953, Toyota began using this system of kanban in the machine shop of their main plant. The company’s leaders knew that the demand for materials would need to be “pulled” by downstream employees, so they developed a system to facilitate that process. By using kanban cards, employees were able to move materials smoothly through the production process. Although there were other manufacturing giants at this time, Toyota took things one step further. Under the direction of Taichii Ohno, the company also recognized the importance of listening to ideas from all employees. In addition, they worked on ways to use their systems for a variety of products or for multiple products at the same time. Soon the successes of Toyota led to the kanban process being used all over Japan. Once the quality of the system was apparent, it began to be used all over the world. By the 1980s, popular American companies like General Electric were using the Toyota system, although calling it by many different names, with much success. The Art of Kanban | creativesafetysupply.com 6 Benefits of Kanban There are significant benefits to implementing a kanban system at your company. These improvements can reduce costs and increase employee morale. It is important to note that employees who feel valued and who are treated with respect will work harder and therefore improve production. Be open to input from your workers, especially in the beginning stages of your kanban system. Doing so will help you see the greatest benefits. The Art of Kanban | creativesafetysupply.com 7 Reductions in Waste and Inventory The kanban system is one that supplies your company with only the materials that it needs when they are actually needed. By doing this, your waste is reduced in several ways. First, you will not waste space by storing excess inventory. As all business people know, space comes at a premium, so it is important to use every bit of space you have in the best possible way. Storing excess inventory is usually not the best use of space. One of the other big drawbacks to holding onto an inventory of components is the risk of having to dispose of them when a part is upgraded. This wastes a great deal of money in addition to the space and manpower needed to deal with the materials. The Art of Kanban | creativesafetysupply.com 8 Flexibility When you manufacture something, production is never on one constant level. Instead there are peaks and valleys that you will need to account for in your business. The kanban system is able to help you meet these needs because the raw materials are shipped to you through the supply and demand process. When production is high you will naturally get more materials delivered to you and when it is low you will get fewer. In addition to controlling materials, this system also allows for quick changeover should you need to manufacture a new product. Since the supply chain is guided by your needs instead of a constant stream of materials and storage, you can switch to a new product whenever that is necessary. Of course, there are limits based on the machinery you have and employee training, but the problem of supply lines will not be an issue. The Art of Kanban | creativesafetysupply.com 9 Cutting Costs Cutting costs is probably the most important feature of a kanban system. If you were to look at your costs for maintaining inventory, you would quickly see that it is quite expensive. When you are able to reduce inventory you are also able to reduce costs. The same can be said for reducing overproduction and costs. All of these things cost money, while a kanban system costs very little to uploads/Industriel/ the-art-of-kanban-streamlining-your-business 1 .pdf