Once You Go Kanban, You Won't Go Back

This is a how-to book which details the step-by-step process to develop three key kanban systems, which are essential for a world-class factory. The book is written to factory personnel who have very little to extensive knowledge of Lean Manufacturing. Written by an expert in Lean Manufacturing with over 22 years of front line practice, including being training in Japan by Shingijutsu. Due to extensive knowledge, and real-world experiences through implementation of these kanban systems at not only The Boeing Company, General Dynamics, and Tesla; but also, at several start-up companies. You will find many illustrations, photographs, and diagrams, which enhance the explanation of these kanban systems: -Supplier Kanban-Material Delivery Kanban-Customer KanbanEffective Supplier Kanban systems manage the flow of the correct amount of parts from suppliers to the factory. A good kanban system nearly eliminates part shortages and overstock. There is detailed explanations on how to analyze shipping history and forecasted sales' projections which is necessary to define your kanban systems. This analysis establishes the average and erratic demands of customers' ordering patterns. Next, you will calculate the daily number of parts that will be consumed in order to meet the customers' demand. Daily consumption knowledge is key in building the Supplier Kanban system. The author step the reader through an activity to determine how many days' worth of parts are needed for each stage of the supply chain, i.e. transportation, receiving, and inspection. For example, all new parts received at factory ABC go through an inspection process. Their inspection team states there is an average ten-day backlog. With this news, you now know 10-days' worth of parts are needed in the pipeline. Each of these supply chain "stages" are investigated to determine the total days' worth needed in the total pipeline ensuring good, usable parts at the factory at the time needed. With this kanban system, a factory can use intuitive visual signals, which simplify communications while also assisting workers who may not be proficient in English. The second type of kanban system is called the Material Delivery system. This system ensures the correct amount of parts are always available to the assembly-line workers at the right time. When parts are readily available, production delays are prevented. Eliminating delays not only increases productivity, but also saves the company money by reducing the need for overtime and wasteful overstock. The third kanban system outlined is the Customer Kanban system. This system is set up between the factory and the customer. It greatly increases on-time delivery and customer satisfaction. Kanban systems significantly enhance factory production efficiency, which saves money, time and boost employee morale. The development of these systems also encourages management to reach-out to factory workers for their valuable input. In each of these stages, employee voices are essential to understand the demands and needs of the factory flow. In the end, the Kanban system methodology is a win-win system for everyone involved.