Creating Kanban & Pull Systems

A Kanban system is a means of controlling the flow of resources by replacing only that which has been consumed. It begins with the shipping of an order to a customer that generates an order to the last operation in the plant or office. When that process step pulls WIP from the next upstream operation, the empty kanban (card) signals that station to replenish the location. This occurs for all operations up the line, including the suppliers of raw materials. A Kanbanl system strictly controls inventory and makes finished products based on actual demand rather than forecasts. This course is typically one day in duration.

Time	Kanban & Pull Systems Course Outline
AM	1. Helper/leader project report out "What's in it for me?" and set event goals
	2. What is a Kanban?
	3. Types of Kanbans Improve communication Types of signals Cards, bar codes, fax, emails, color coded balls
	4. Why do Kanbans? Improve communication Reduce inventory Improve customer satisfaction Reduce waste
	5. Prerequisites for Kanbans
	6. Kanban Rules - Involve whole supply chain
	7. Pick Part numbers to Kanban
	8. Kanban Rules - Quality at the source
	9. Kanban Rules - TPM program in place
PM	1. Kanban Rules - Use parts that have stable demand
	2. Calculate quantity for each location
	3. Kanban Rules - Parts delivered to point of use
	4. Kanban Rules - Kanban container return areas
	5. Pick type of signal & standard container
	6. Kanban Rules - Begin changeover reduction efforts
	7. Calculate number of containers
	8. Kanban Rules - Plan for adjustments
	9. Student teach back - Review key learning elements & understanding
	10. Report out to management / organization
	11. Post Kanban project results in a public area