Chinese name: Kanban mbth: spectaculars Main ideas: follow the principle of internal users and other production functions; Master production planning warehouse management and other operating principles: Kanban management, such as the operation principle, types and uses of defective products, production functions, work rules, system composition, reference functions, Kanban management, Kanban management is a kind of card, which indicates when a certain process needs a certain material and how much it needs, and is also called a calling card. There are two kinds of kanban, namely conveying kanban and production kanban. The conveying kanban is used to guide the parts to move between the first and second processes. When the container where the parts are placed is transported from the export warehouse of the previous process to the import warehouse of the next process, the transport kanban is attached to the container. When the next process starts to use the parts in the container in its entrance warehouse, the transfer kanban is removed and placed in the kanban box. The operation steps of kanban management Production function 1 and the theory of master production plan Kanban management do not involve how to prepare and maintain the master production plan, but start with a ready-made master production plan. Therefore, enterprises adopting JIT production mode need to rely on other systems to make master production plans. 2. Material Requirements Planning Although enterprises that adopt Kanban management usually outsource warehouses to suppliers for management, they still need to provide suppliers with a long-term and rough material requirements plan. The general practice is to obtain the planned consumption of raw materials according to the one-year finished product sales plan and sign a package order with suppliers. The specific demand date and quantity are completely reflected by kanban. 3. Kanban management of capacity demand plan does not participate in the formulation of master production plan and naturally does not participate in the generation of capacity demand plan. Enterprises that realize kanban management realize the balance of production process through process design, equipment arrangement, personnel training and other means, thus greatly reducing the phenomenon of unbalanced production capacity and demand in the production process. Kanban management can quickly expose processes or equipment with excess or insufficient capacity, and then eliminate problems through continuous improvement. This method of analyzing the root of the problem and solving the problem is worth learning. 4. Disadvantages of warehouse management order point method: the backlog or shortage of warehouse inventory cannot be solved by kanban management. After adopting kanban management, the quantity of materials received by the production line from the warehouse is controlled within the kanban quantity, and the quantity of materials ordered by the warehouse cannot exceed the kanban quantity, which can partially solve the inventory backlog problem. In the automobile manufacturing industry where Kanban management is widely used, in order to solve the problem of warehouse management, the method of outsourcing the warehouse to the supplier management is often adopted, which requires the supplier to provide the required materials at any time, and the transfer of material ownership occurs at the same time as the production line receives the materials. This is essentially throwing the burden of inventory management to suppliers, who bear the risk of occupying inventory funds. The prerequisite for this is to sign a long-term package with suppliers, reduce sales risks and expenses, and be willing to bear the risk of inventory backlog. 5. WIP management in production line The key to realizing JIT production mode is to control the number of WIP within the number of kanban, and to determine a reasonable and effective number of kanban. 6. Technical Support Some enterprises neglected the technical support system of Kanban management, which led to the failure of practice. According to the experience of Toyota Motor Corporation of Japan, it is impossible to completely straighten out the production process by simply adopting Kanban management. We should start with the rationalization of production process, constantly improve operation methods and production conditions, and then gradually transition to kanban management. It can be seen that whether there is a technical support system is the key to realize kanban management. 7. Personnel quality requires enterprises to implement kanban management, which not only requires employees to carry out standardized operations under normal circumstances, but also requires employees to solve various unexpected problems in the production process as soon as possible to ensure the smooth progress of the production process. 8. Just-in-time production has a narrow scope of application in applicable industries, and it is usually only used by enterprises that use assembly lines to manufacture or assemble products. The typical industry is automobile manufacturing. However, some management ideas in JIT production mode, such as eliminating waste and overproduction, flexible production plan, rapid adjustment of equipment, and full participation in improvement activities, are of reference significance to all enterprises. Operating principle of working rules 1. Whether it is production kanban or delivery kanban, it must be attached to the container with parts. 2. The parts must be extracted by the demander to the supplier's workplace through the transportation kanban, or the demander signals the supplier, and the supplier transfers the parts through the transportation kanban. In a word, the parts should be delivered according to the buyer's requirements, and delivery cannot be made without delivery kanban. 3, to use standard containers, are not allowed to use non-standard containers or use standard containers but not according to the standard quantity. Doing so can reduce the processing and counting time and prevent parts from being damaged. 4. When the production kanban is taken out of the production kanban box, only the number of parts contained in the standard container is produced. 5. Defective products shall not be handed over to the next working procedure. Category and usage 1, Kanban in progress. Refers to the kanban used for processing in a certain process. This kind of kanban is used in assembly lines and processes that do not need a lot of work replacement time (the work replacement time is close to zero), even if various products are produced, such as processing flows. The so-called kanban is also called a card, but in fact the form of kanban is not limited to a certain card form, which records all kinds of information. The essence of kanban is an information medium, which can give production instructions to required parts at the required time and quantity, and there are various forms to realize this function. For example, Toyota's factory uses small balls, round wheels and trolleys as billboards. With the popularization and improvement of computer graphics, the practice of setting up computer terminals in each process and displaying kanban information on the computer screen is introduced more and more. 2, signal kanban. Signal kanban is a kanban used in mass production. Such as stamping process, resin forming process, die forging process, etc. Different from the above-mentioned work-in-process kanban, the special items that must be recorded in the signal kanban are the processing batch and reference number. Processing batch refers to the quantity that should be processed at one time when the signal kanban is removed. The benchmark figure shows that there are still several hours of inventory from the time the kanban is removed, that is to say, there are still several hours from the time the kanban is removed to start production. 3. Kanban between processes. Kanban is used to collect the parts needed from the post-process to the pre-process in the factory. 4. Kanban for external orders. This kind of kanban is similar to the inter-process kanban, except that the "pre-process" is not in the factory, but an external cooperative manufacturer. The name of the purchasing unit and the purchasing progress shall be recorded on the foreign order board. 5. temporary kanban. Kanban for equipment safety, equipment maintenance, temporary tasks or overtime production. The electronic kanban system is mainly composed of kanban controller and display terminal. Display terminals to which the controller can be connected include various displays and flat-panel TVs. Production quantity, time, method, sequence, delivery quantity, delivery time, delivery destination, placement place, delivery tools and other information. They are all recorded in the kanban of the production and delivery work instructions, and traced back from the assembly process to the previous process one by one. The kanban carried on the used parts is removed on the assembly line for collection in the previous process. Realize "post-process collection" and "timely and moderate production" through kanban. 2) Kanban must be used in accordance with the established application rules to prevent over-production and over-delivery. One of the rules is: "You can't produce or transport without kanban." According to this law, if the number of kanban is reduced, the output will be reduced accordingly. Because kanban only represents the necessary quantity, it can automatically prevent overproduction and correct delivery by using kanban. 3) Another application rule of tool kanban for "visual management" is: "Kanban must be stored in real objects" and "The previous process should be produced in the order of removing kanban". According to this rule, the management personnel on the job site can see the priority of production at a glance, which is easy to manage. Moreover, you can know the job progress, inventory and so on in the post-process just by looking at the boards. 4) Improved tools reduce the intermediate storage of WIP by continuously reducing the number of kanban in JIT production mode. Generally speaking, if the inventory of WIP is high, even if the equipment fails and the number of defective products increases, it will not affect the production of the next process, so these problems are easily covered up. And even if there is a surplus of staff, it is not easy to detect. According to one of the application rules of Kanban, "Defective products cannot be sent to the next process", if the requirements of the next process cannot be met, the whole line will be shut down, which will immediately expose the problem, so improvement measures must be taken immediately to solve the problem. In this way, through the improvement activities, the problem has not only been solved. It also makes the "physique" of the production line continuously enhanced, which brings about the improvement of productivity. The goal of JIT production mode is to finally realize the inventory-free production system, and Kanban provides a tool to move in this direction. Kanban mode The so-called Kanban mode is a production management mode developed and adopted by Toyota Motor Corporation to reduce inventory. It is a management method that aims at just-in-time system and produces (prepares) the required products according to the required quantity when needed, and takes this as the basic concept. Because the so-called "Kanban" with both operation instruction cards and field cards is the central means, it is called "Kanban mode".