Kanban Made Simple. Demystifying and Applying Toyota's Legendary Manufacturing Process 

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• 1. Table of Contents

• 2. BackCover

• 3. Kanban Made Simple - Demystifying and Applying Toyota s Legendary Manufacturing Process

• 4. Preface

  The Best Way to Read this Book

• 5. Acknowledgments

  Acknowledgments

• 6. Chapter 1: Introduction to Kanban

  A Short History of Kanban

• 7. What Is Kanban

  What Is Kanban

• 8. Why Implement Kanban Scheduling

  Why Implement Kanban Scheduling Reduces Inventory Improves Flow Prevents Overproduction Places Control at the Operations Level (with the Operator) Creates Visual Scheduling and Management of the Process Improves Responsiveness to Changes in Demand Minimizes Risk of Inventory Obsolescence

• 9. Kanban Implementation Process

  Kanban Implementation Process Step 1: Conduct Data Collection Step 2: Calculate the Kanban Size Step 3: Design the Kanban Step 4: Train Everyone Step 5: Start the Kanban Step 6: Audit and Maintain the Kanban Step 7: Improve the Kanban

• 10. It Takes a Team to Be Successful

  It Takes a Team to Be Successful

• 11. Do You Need a Consultant?

  Do You Need a Consultant?

• 12. Choosing the Target Process or Department

  Choosing the Target Process or Department

• 13. Keys to Successful Implementation of Kanban

  Keys to Successful Implementation of Kanban

• 14. Using the Workbook as a Guide

  Using the Workbook as a Guide

• 15. What s in the Appendixes

  What s in the Appendixes

• 16. Summary

  Summary

• 17. Notes

  Notes

• 18. Chapter 2: Forming Your Kanban Team

  Overview

• 19. How Should I Select the Team?

  How Should I Select the Team?

• 20. Appoint a Project Leader to Guide the Team

  Appoint a Project Leader to Guide the Team

• 21. Set Up Team Rules and Develop Group Process

  Set Up Team Rules and Develop Group Process

• 22. Develop a Plan for Implementing the Kanban

  Develop a Plan for Implementing the Kanban Develop a Timeline Set a Team Budget

• 23. Make Sure the Team Gets Training

  Make Sure the Team Gets Training

• 24. Provide the Team with Management Support

  Provide the Team with Management Support

• 25. Using the Workbook

  Using the Workbook

• 26. Summary

  Summary

• 27. Chapter 3: Conduct Data Collection

  Overview

• 28. Gather Data

  Gather Data Number of Parts Produced by the Target Process Changeover Times Downtime Scrap Levels

• 29. Document Your Findings

  Document Your Findings

• 30. Analyze the Data

  Analyze the Data

• 31. Two Examples

  Two Examples

• 32. Using the Workbook

  Using the Workbook

• 33. Summary

  Summary

• 34. Chapter 4: Size the Kanban

  Overview

• 35. Determining the Replenishment Cycle

  Determining the Replenishment Cycle

• 36. Implications of Scrap, Unplanned Downtime, and Changeover Times on Replenishment Intervals

  Implications of Scrap Unplanned Downtime and Changeover Times on Replenishment Intervals

• 37. Calculating the Buffer

  Calculating the Buffer Customer Delivery Requirements (and Your Promised Service) Internal Lead Times Supplier Lead Times Comfort Level Determining the Final Buffer Size

• 38. Calculating the Number of Kanban Containers

  Calculating the Number of Kanban Containers

• 39. Perform a Reality Check

  Perform a Reality Check Container Sizes Incorrect Production Data Incorrect Buffer Assumptions Incorrect Capacity Assumptions Reconciling the Problem

• 40. An Alternate Method for Sizing Your Kanban

  An Alternate Method for Sizing Your Kanban

• 41. Supplier Kanbans

  Supplier Kanbans Setting Up Supplier Kanban Quantities

• 42. Finished Goods Kanbans

  Finished Goods Kanbans

• 43. Calculating the Benefits of Proposed Kanban

  Calculating the Benefits of Proposed Kanban

• 44. What About Economic Order Quantities vs. the Calculated Kanban Quantity?

  What About Economic Order Quantities vs. the Calculated Kanban Quantity?

• 45. Using the Workbook

  Using the Workbook

• 46. Summary

  examples on how to calculate kanban quantity how to calculate buffer quantity in kanban

• 47. Chapter 5: Developing a Kanban Design

  Overview

• 48. Team Activity

  Team Activity

• 49. Develop a Concept That Works for Your Organizational Culture

  Develop a Concept That Works for Your Organizational Culture

• 50. Kanban Cards

  Kanban Cards

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