It’s very important to first know the rules and regulations that guide this scheme. You should note the rules, if well implemented, will yield very positive results and thus prove that Kanban can be a success if used in any settings. The rules have been used by various companies seeking to find solutions in areas were development is lagging and there is very little or no improvement at all.
They can be used alongside lean management and the kaizen principle to ensure that everything in the company is progressing in a forward direction. Some of the basic rule is:
- Ensure that good approved to go to the next stage of production are not of substandard quality
- You should only produce what is needed and can be sold
- Manufacture the exact amount of products that can be cleared out in a single cycle
- Sustain the process for as long as possible
- Smoothen the cycle by reducing the number of surplus products produced
The Three Cycles In The Kanban Scheme Mostly Consists Of
You should ensure that all of them are placed in bins in the form of a card that can be used to convey a message to workers and the senior employees. The scheme is more of a bin system that can be used to help the workers identify various manufacturing prospects tat the company is trying to achieve.
They should also contain a detailed explanation of what the product being manufactured is all about and any other detail that might be of importance. The bins will be taken back to the storage room each time they are out of cards.
This would mean that the bin representing demand has no more cards signifying that resources are needed and should be purchased. Significantly, the bins should be returned to place once they are filled with the Kanban cards so that work can resume with ease.
The supplier bin is very ideal since it keeps the management on toes ensuring that the company doesn’t lack any form of product that has a sale value. The management can choose to add a spare bin to the Kanban scheme for convenience purposes. The spare bin can contain the various undocumented and misunderstood production processes such as miscellaneous activities.
You should however note that this bin is strictly for time saving so that people don’t waste a lot of time on what they practically can’t understand. It should therefore be sorted out once time is made available and put into its respective bin.
Kanban is a philosophy that is utilized in sustaining the compilation of company assets and requirements. Kanban operates by sending a message to manufacture and transport a new product as the resources are being utilized. The messages are sent through a self restoring sequence of events that are continuous in the same order thus enlightening both the manufacturers and purchases on the different aspects of Kanban. Kanban has over the years been used to improve kaizen job and kaizen supplies putting up a system that promotes continuous improvement. However, a lot of people often assume that Kanban is a system used to sustain an inventory which is in fact not the case. Kanban can be described as more of a planning methodology that facilitates workplace prospects such as what to manufacture, when to manufacture it and finally amount to manufacture.
One Of the Most Successful Companies
To Implement Kanban, Toyota, did so by continuously sticking to its fundamentals irrespective of the slow and gradual continuous improvement in every sector of the company. In the long run, the Kanban system grew to be a very vital tool in sustaining the entire manufacturing business. It further showed that it was a very ideal way of enhancing continuous improvements for both kaizen jobs and kaizen supplies.
The Kanban fundamentals were initially coned from how supermarkets operate and handle their business. The ideology was that most supermarkets strictly purchase wholesale products that will clear from their shelf in the least time possible especially if they are perishable goods. Supermarkets don’t fancy putting products that has a long shelf life in terms of sales as this will greatly injure their profits. In generals, the Kanban fundamental can be described in simple terms as cyclic shelf stocking where only required goods come and go on a regular basis.
This technique is very ideal for both the seller and buyer in that the seller clears out their products effectively while the buyer gets exactly what they came for; convenience in the making. The companies therefore emulated this technique by stocking only things that had sale value to customers. The customers on the other hand received mostly what they were looking for and were satisfied with the company’s stock provision policy. However, thorough research had to be done so as to identify the major items that consumers were greatly attached to. They also had to add any advancement and changes that would appeal to the consumer and thus attract them into buying.
You should first know a little history behind the kaizen process before being able to successfully implement it. Understanding the origin will give you a wider understanding of the kaizen philosophy and how it can bring continuous improvement in whatever industry sector you are involved in.
The Kaizen Philosophy
The Kaizen philosophy was created by the Japanese sometimes after the Second World War. It was created as strategic formula to develop the country after it was brought down to its knees during the war. A lot was damaged and the progress the country had been initially making had been stalled.
It was therefore considerate to come up with the kaizen philosophy that would oversee the continuous improvement of a country that was at its low. The kaizen philosophy was implemented in the various industries and companies within the country. A program was developed as well which was mostly used in educating people on how to implement the kaizen philosophy into their business.
Companies implementing the kaizen principles know that they should immediately seize any form of production if they notice anything peculiar with the process. This is because the abnormality can back track any progress made and therefore reverse the kaizen process since you’ll no longer be improving.
The management can however ensure that the abnormality is identified and either removed or rectified. This will ensure that things resume to normalcy and continuous improvement is achieved.
Some of the procedures under the kaizen process are:
- Level or smoothen the different processes of production
- Identify the amount of processes i.e. duration each cyclic process consumes and the maximum capacity that the inventor can be able to take.
- Compare and contrast capacity to produce with need to produce
- Input creativity where necessary in order to fulfill company obligations and hence add value to revenue
- Sustain the process indefinitely
The kaizen burst, also known as the kaizen event, is a more detailed principle that can be used to bring direct impact in terms of continuous improvement. The main objective of the kaizen event is to ensure tat all efforts are directed to activities that are productive and can bring about fast improvement.
This does not, however, mean that any activity that doesn’t generate income should be shelved. It only means that an order of priority should be utilized at all time to identify what come first in he list. The kaizen event was also utilized to ensure that there was very little waste being produced due to lack of prioritization.