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Ways To Schedule Batch Processes With Kanban: - Pattern Production

This document discusses different methods for scheduling batch processes using kanban, including pattern production, lot making with a batch board, and using a triangle kanban. It provides steps for setting up a triangle kanban system, including determining changeover time available, setting the number of changeovers per day, establishing a batch factor and lot sizes for parts, and determining the trigger point for reordering. The goal is to balance production and changeover times to maximize efficiency.

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355 views10 pages

Ways To Schedule Batch Processes With Kanban: - Pattern Production

This document discusses different methods for scheduling batch processes using kanban, including pattern production, lot making with a batch board, and using a triangle kanban. It provides steps for setting up a triangle kanban system, including determining changeover time available, setting the number of changeovers per day, establishing a batch factor and lot sizes for parts, and determining the trigger point for reordering. The goal is to balance production and changeover times to maximize efficiency.

Uploaded by

Trần Thị Hồng Tâm
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Ways to schedule batch

processes with kanban 8 hour cycle

•Pattern production P1 P2 P3 P4 P5 P6
+Predictable sequence, stability
-Inflexible to changes during shift Sequence fixed, part time variable

Part # Part # Part # Part # Part # Part #


•Lot making with batch board
+Visual control, shorter lots possible, info
-Many cards per part #, requires discipline Trigger
Point

Full Empty

Part # Part Description Location

•Triangle kanban Date Triggered Lot Size

+Single kanban to control, pressure to reduce C/O time


-Fixed quantity unfixed time cases only Trigger Point

Machine #

Tool #
Sample triangle kanban flow

Inventory Signal kanban rail


Batch Process
C 2
Current Next

Delay 3
Emergency
Part # 15456
1 15456
15455
15454

Part # 15455 Part # 15454

Note: Only 1 triangle kanban per part # is needed in this flow


Triangle Kanban
Part # Part Description Location

Date Triggered Lot Size

Trigger Point

Tool #

Machine #
Short exercise - Steps for setting up
triangle kanban*

Step 1: Determine time available for changeover work.


Step 2: Set the number of changeovers per day. Step
3: Establish a lot size for production. Step 4: Establish
a trigger point for reorder.

*Assumes part numbers have already been dedicated to run on certain machines
Step 1: Determine time available for non-
production work (1 machine*)
Part # Average demand Cycle time Required run Average Average
per day (pieces) Per piece time per day changeover time scrap rate
15487 200 40 sec. 136 min. 55 min. 1.5%
15488 300 45 sec. 228 min. 55 min. 1.3%
15489 500 40 sec. 339 min. 55 min. 1.5%
1,000 703 min.

Total 1-shift production time available (net breaks and lunch) 450 min.
Number of shifts x 2
Time available for production on 1 machine 1 day = 900 min.
Time required per day to meet average demand* - 703 min.
Net time available for set up and changeovers per day = 197 min.
* Taken from above chart on basic machine data

*The three part numbers dedicated to this molding machine


Step 2: Set the number of change over
events per day

197 min.
Non-production time available
Average downtime (not including set-up and changeover - 30 min.
times)
Time available for changeover work on 1 machine 1 day = 167 min.
Average changeover time ÷ 55 min.
Desirable number of changeovers per day = 3.04
Step 3a: Establish the batch factor

Number of part numbers on the machine


Batch Factor =
Number of C/O’s per day

In this 3 part numbers


molding = 1
3 C/O’s
machine
example

Lot Size= 1 day of production per part number


Step 3b: Establish the lot size

Part # Batch factor Demand per day Lot size


(pieces) (pieces)

15487 1 x 200 = 200

15488 1 x 300 = 300

15489 1 x 500 =
500 Total

1000 pieces
Step 4: Establish the trigger point for
reorder

Trigger point = Total lead-time to replenish Part


takt time

Part # Daily run time C/O time First Average Total LT (min)
container down time*
15487 136 55 10 4.4% 210

15488 55 10 4.4% 306


228
15489 339 55 10 4.4% 421

*Inclusive of scrap loss


Step 4: Establish the trigger point for
reorder (continued)

Part # Lot size Total LT Longest Takt time Trigger


(Pieces) lead-time* (27,000*2/ Point**
(Min) Daily demand)
(min)

15487 200 210 421 4.5 min 100

15488 300 306 421 3.0 min


140
15489 500 421 306 1.8 min 170

*Assumes longest run time item at front of queue for the three part numbers.
**Rounded to the nearest 10 (box quantity)

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