Mikrologisticheskaya system KANBAN (in Japanese - the map) is one of the first attempts of practical implementation of the concept of "just in time" corporation Toyota Motor. KANBAN system represents the first implementation of the "pull" mikrologisticheskih systems in production, the introduction of which from the beginning of the development of the firm Toyota took about 10 years. Such a long period was due to the fact that the system could not work without the proper logistics surrounding the concept of "just in-time, key elements of this environment were:
• rational organization of production and balance;
• universal quality control at all stages of the production process and quality of raw material resources from suppliers;
• partnerships with reliable suppliers and carriers;
• increased professional responsibility and high labor discipline for all staff.
Thus, the system combines KANBAN features of the system "just in time", in particular, the small size of the stock and the individual production units. System is often used in regular production large volumes of products, but less suitable for large or expensive items (the cost of their storage in a warehouse or shipping large).
Initial attempts American and European competitors will automatically move scheme KANBAN in the production of excluding these and other factors, logistic environment suffered failure.
Mikrologisticheskaya system KANBAN, first used Toyota Motors Corporation in 1972 at the plant "Takahama" (Nagoya, Japan) is a system of organization continuous production flow, capable of rapid restructuring and require almost no insurance stocks. The essence of the system is KANBAN that all production units of the plant, including the final assembly line, are provided with resources in quantity and in terms that are necessary for of the order, given subdivision, the consumer.
Thus, unlike the traditional approach to the production of a structural unit of Production has no general rigid production schedule, and optimize their work within an order unit firms carrying out operations on the follow- stage of production and technological cycle.
means of conveying information in a special card "kanban" in a plastic envelope. Distributed two types of cards: the selection and production order. In a card selection indicates the number of parts (components, semi-finished products) that must be taken at the previous site of processing (assembly), while in the card production order - the number of parts to be manufactured (assembled) at the previous stage of processing. These cards are circulating inside the company's Toyota, as well as between the corporation and to cooperate with companies, as well as in enterprises of branches. Thus, the card "kanban" carry information about the amounts spent and manufactured products, which allows for the concept of "just in time."
With operations in the KANBAN system uses the following rules of two cards of "kanban":
1. Can not be manufactured any product until long as the card production order does not permit production.
workers can perform the maintenance work, carry out cleaning or working on projects to improve up until you arrive card production order. Accordingly, card selection controls the transport of goods between sections of processing (assembly).
2. Can only apply the standard containers, they are always filled with the prescribed small volume production.
3. To the container just have one card selection, and one card production order.
main indicators of such a system are volume of the container and the number of them in the system. Control is very accurate, flexible and sensitive, prevents the undesirable increase the level of reserve.
consider the classical example of the system KANBAN.
the manufacture of products A, B, C on the assembly line used parts a and b are made on the previous process stage (production line). Parts a and b are produced in the preceding stage, stores along the conveyor, attaching thereto Card Order "kanban". Work with assembly line manufactures products A, on the truck or truck from a technology comes with a card orders to place storage items and to take a certain number of boxes of parts with attached card selection. On-site warehouse worker loads a loader (technology truck) the necessary number of parts and according to the card selection, while removing boxes from the previously attached to them card production order. He then delivers the received details of the assembly line with a selection of cards, "kanban". At the same time the card production order remain in place storage details while the production line, showing the number of items taken. They form an order for new parts, g, the amount of which will be in strict conformity the quantity specified in the card production order "kanban".
Since the system supports a minimum level of reserves to provide continuous work of industrial-technological areas and personnel, and adjusted by means of calculating the average daily demand in every detail and definition appropriate number of cards "kanban". When material resources are spent, the card order "kanban" is sent to suppliers to replenish their reserves. So as the projected amount of time and supplies are low, commissioned by the party are small. In addition, the stock of which is preserved for the period of delivery, maintained at a minimum.
Another example that illustrates how the system mikrologisticheskoy KANBAN
There are two processing centers (OC): 0TS1, use the details to make a semi-finished and OTS2 using semi-finished products for the manufacture of products C. Before applying the technology KANBAN must decide how many units of each item range can fit on the container. In the system there is no storage on the ground, since only used containers moved from one OC to another through technological transport. Each container is completely filled has a card attached to it "kanban" with the following information:
• Code components (semi-finished products, work in progress);
• description;
• products (final, intermediate), where these components are used;
• number (code working), which produces components;
• Number OC (code working) that uses the component;
• the number of components for the container;
• number of containers (cards "kanban") next to the OC. Cards "Kanban" may be of two colors: black and white.
White cards are on the containers at the entrance ("in") for OTS1 and OTS2 and are intended for transportation. Black Card "kanban" are on the containers at the exit ("out") and the mean resolution for processing. Information on cards attached to the containers, applies to a particular container and record the volume and the corresponding above-mentioned particulars. In the management of each operation in logistics technology involved KANBAN Only free cards, which are separated from the container.
Black Card component C is the output for OTS2. In this case, it denotes a decision for OTS2 (working at this center) to produce as many units of component C as needed to fill the empty container. In this process uses OTS2 a container with the items in the filed at the entrance OTS2, releasing a cursory card "kanban", which gives permission to transport the container to another In parts of OTS1 (its output) to the input OTS2. Work on the truck with the container and freed a white card arrives OTS1 where a container filled with In detail, removes black card and leaves it next to an empty container, and he attaches a white card on the container filled with parts B and transports him to OTS2 ..
free black card is the order for OTS1 on production of the next container of parts B. In the process of manufacturing the container is released And with the details, and white card is a signal to the supplier for replenishment of parts A to one container, etc. In spite of the fact that mikrologisticheskaya system KANBAN production generated by the conveyor, its principles can be applied throughout the supply chain for any type of production. KANBAN - a typical "pulling" mikrologisticheskaya system whose main objective is to produce only the required number of products in accordance with the demand of a finite or an intermediate consumer. For example, when parts are needed on the assembly line, they come with the previous industrial site along the chain in the required number and at the right time. And so on throughout the supply chain of production.
KANBAN system significantly reduces the stock of material resources at the input and work in progress manufacturing output, allowing you to identify bottlenecks in the production process. When the problem is solved, the volume of buffer stocks to fall again, until do not show up the next bottleneck. " Thus, this system allows you to create a balance in the supply chain by minimizing inventory at every stage.
Practical use of KANBAN, and then its modified versions can significantly improve product quality, reduce logistics cycle, thereby greatly increasing the turnover of working capital firms to reduce production costs, virtually eliminate the insurance reserves and significantly reduce the amount of work in progress. Analysis of the global experience of the system mikrologisticheskoy KANBAN many well-known engineering firms shows that it provides an opportunity to reduce inventories by 50%, trade - 8% with a significant acceleration of turnover of circulating means and improving the quality of the finished product.
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