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1、1 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/061 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated with
2、out written authorisation.Rev 6:30/09/06What Is A KanBan System?Where process steps are controlled by downstream customer pull.上一步工序安排由下游客户需求拉动Kanban provides authorization to perform work to replenish material.看板为补足原料（时间、地点、数量等）提供了授权Kanban signals(cards,electronic signal or similar mechanisms)are h
3、ighly visible to all employees.看板信号（卡片、电子信号或类似机构）容易被所有员工识别Kanban 看板=Signal 信号Customer“Pull”Drives Processing客户的需求驱动生产客户的需求驱动生产2 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/062 SM
4、MT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06THE SIX RULES OF KANBAN看板守则六条看板守则六条lThe consuming process withdraws only what is needed.使用的工序仅使用它需要的东西使用的工序仅使用它需要的东西lProduce to replen
5、ish only what is withdrawn by the next process.下一个工序的消耗导致上一个工序的生产来补足缺口下一个工序的消耗导致上一个工序的生产来补足缺口lDo not send defective products to the next process.不要将不良品流到下一个工序不要将不良品流到下一个工序lParts must not be produced or moved when there is no kanban.没有看板信号时材料不能生产或移动没有看板信号时材料不能生产或移动没有看板信号时材料不能生产或移动没有看板信号时材料不能生产或移动lKan
6、ban must be attached to the actual parts or container.看板必须附在实物或者容器中看板必须附在实物或者容器中lThe number of parts in the container must match the kanban.容器中材料数量必须和看板上数据保持一致容器中材料数量必须和看板上数据保持一致3 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communica
7、ted without written authorisation.Rev 6:30/09/063 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06Two Bin Systems双单元系统双单元系统The most simple type of replenishment system 最简单的补充系统Uses
8、 two containers dedicated to one component and one location(point of use)使用两个容器供应一种材料，并放在同一个地点（一个加工处）Each container is identified with the part reference,the full container quantity,the point of use at the line and the replenishment location in the warehouse 每个容器上应标明存放材料名称，容量，生产线上使用的环节以及在仓库中补充材料的地点4
9、 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/064 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated witho
10、ut written authorisation.Rev 6:30/09/06When one container is empty it is taken away and refilled,then it is returned to its point of use.当一个容器内的材料用完，带走该容器，补足材料后，返回至原来的位置The quantity of components in the container is greater than the number consumed while the other container is being refilled 当一个容器在补
11、充材料时，另一个容器内的材料剩余数量应大于消耗数量Two Bin Systems双单元系统双单元系统Consuming processFull BinEmpty Bin5 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/065 SMMT/SBAC Industry Forum 2006-8.This documen
12、t is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06Two Bin Systems双单元系统双单元系统6 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisa
13、tion.Rev 6:30/09/066 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06Internal KanBan Example内部看板系统示例内部看板系统示例5.Material replenished within pre-set cycle time 根根据据提提前前设设定定好好的的周周期期时时间
14、间补补足足材材料料4.Electronic pull signal sent to warehouse and generates a pick note 扫描信息发送至仓扫描信息发送至仓库，生成领料单库，生成领料单7.Material moved to line-side when location is empty当线当线上材料用完上材料用完后，补充材后，补充材料移至线上料移至线上1.Material consumed by line生产线消耗生产线消耗材料材料Kanban Buffer看板库存区看板库存区Line-side Stock线上库存线上库存Warehouse仓库仓库2.Kanb
15、an Card moved from container to collection point 看看板卡由容器转移到收集板卡由容器转移到收集点点3.Kanban Card moved from collection point,scanned and placed on kanban board看板卡扫描后转移到看板看板卡扫描后转移到看板墙上墙上6.Kanban Card Returned to container on delivery to Kanban buffer看板卡在材料交付至看板库看板卡在材料交付至看板库存区后返回容器内存区后返回容器内Warehouse pick note c
16、ontains delivery point for material仓库领料单包括交付地点仓库领料单包括交付地点7 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/067 SMMT/SBAC Industry Forum 2006-8.This document is the property of the ab
17、ove company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06What Is A KanBan System?什么是看板系统？什么是看板系统？What information does a Kanban system provide?看板系统提供怎样的信息？The number of units required.零件/原材料的需求数量Where the units are stored.零件/原材料的存放地点Where the units are process
18、ed.零件/原材料的加工地点It is the authorization to do something.需要做的动作When units are require.何时需要这些零件/原材料The priority in which units should be supplied.零件/原材料供应的优先级8 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written auth
19、orisation.Rev 6:30/09/068 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06A replacement system:produce what has been removed.移位系统：生产被拿走的产品Last process gets customer orders.最后一个工序拿到
20、客户订单This process takes material out of buffer.该工序拿走缓冲库存中的材料Kanban signals upstream process to act.看板给信号到上游工序做出反应KanBan Flow Signal To Produce看板流看板流 生产的信号生产的信号9 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written
21、authorisation.Rev 6:30/09/069 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06KanBan Signal TypesA Card.一张卡片A Bin/Container.一个盒子An empty floor location.一块空地An empty rack location.一
22、个空支架An Electronic message(e.g.E-mail,EDI).电子信息（邮件，电子数字信号）Visual signal(e.g.Light).视觉信号（光）看板信号的类型看板信号的类型10 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/0610 SMMT/SBAC Industry Foru
23、m 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06For Kanban systems to be properly implemented,we must ensure:为了确保看板系统的正确实施，我们必须确保：Level Demand of Work Load(Heijunka)均衡化的需求 Stable Processes 稳定的过程Pre-Condi
24、tions For KanBan:看板看板的前提条件的前提条件11 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/0611 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot b
25、e reproduced or communicated without written authorisation.Rev 6:30/09/06SupermarketsIn a food supermarket:在食品超市/生产超市：Typically there is a standard amount of each item on the shelves.典型的超市架子上有一定标准量的货物People take what they need and stock is replenished by stock people.人们拿走他们想要的，然后负责库存的人员会将其补足Supplier
26、s bring new goods according towhat has been sold.供应商根据销售补足新的货物There is no place to overstock goods.超市没有地方存放多余的库存Many items are perishable(e.g.,milk).很多货物是容易变质的（例如：牛奶）超市超市12 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated wit
27、hout written authorisation.Rev 6:30/09/0612 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06Supermarkets in ProductionThink of goods as perishable.把产品当做是容易变质的Lot sizes should be sm
28、all to facilitate quick reaction to changes in demand.小批量可以更快地根据需求的变化作出反应Processes should get only what is needed from the preceding process.每个环节必须根据前一个环节的需求进行Preceding processes should have a given amount of stock storage.When it is full,they should become idle.之前的每一个环节都需要有一定量的库存。当库存满足就应保持闲置。“When
29、the cup is empty,fill it up”生产中的超市生产中的超市13 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and cannot be reproduced or communicated without written authorisation.Rev 6:30/09/0613 SMMT/SBAC Industry Forum 2006-8.This document is the property of the above company and
30、 cannot be reproduced or communicated without written authorisation.Rev 6:30/09/06Supermarket Pull System(Using Kanban)20 WCustomerProcessSupplyingProcessWithdrawalKanban取货看板取货看板ProductionKanban生产看板生产看板Customer Process 客户过程Goes to the supermarket and withdraws what it needs when it needs it 当你需要的时候随时随地去超市拿取即可Supplying Process 供应过程Produces/delivers to replenish what was withdrawn生产/提供以此补充被拿走的货物超市拉式系统（使用看板）超市拉式系统（使用看板）