Kanban management is an important concept in Toyota production mode, which refers to a tool to control the on-site production process to realize just-in-time production mode.

The Purpose and Significance of Kanban Management

(A) the transmission of on-site production information, unified thinking, there are many people at the production site, and the phenomenon that information transmission is not timely due to different division of labor occurs from time to time. After the implementation of kanban management, anyone can know the production information on the spot in time from kanban, and master their own work tasks from it, so as to avoid omissions in information transmission. In addition, in view of the problems in the production process, the production personnel can put forward their own opinions or suggestions, and most of these opinions and suggestions can be displayed and discussed through billboards, so as to unify the employees' thoughts and let everyone work towards the same goal. (2) Eliminating the loopholes in on-site management Through kanban, the production site manager can directly grasp the current situation of production progress and quality, and provide a direct basis for his control decision. (3) Fairness and transparency of performance appraisal Through kanban, the performance of the production site can be seen at a glance, which makes the performance appraisal of production open and transparent, and also plays a role in encouraging the advanced and urging the backward. (4) Ensure the operation order of the production site and enhance the company's image. On-site kanban can not only prompt operators to operate according to kanban information, but also make on-site operations orderly, leave a good impression on customers who visit the company's site and enhance the company's image. Kanban Type (1) Triangle Kanban mainly serves "5S" management. Kanban content mainly indicates the names of various items, such as finished product area, semi-finished product area and raw material area. Kanban is uniformly placed in a fixed position in the area divided by the site. (II) Equipment Kanban Equipment Kanban can be pasted on the equipment or placed in a suitable position around the equipment, without affecting people flow, logistics and operation. The content of the equipment kanban includes the basic situation of the equipment, the spot check, the schematic diagram of the spot check position, the main fault handling process, management responsibilities, etc. (III) Quality Kanban The main contents of quality kanban include daily, weekly and monthly quality status analysis, quality trend chart, quantity and description of quality accidents, employee skill status and departmental policies. (IV) Production Management Kanban The content of production management Kanban includes operation plan, planned completion rate, production progress, equipment operation and maintenance status, workshop organization structure, etc. (V) Process management kanban Process management kanban mainly refers to kanban used between processes in the workshop, such as picking kanban, cutting kanban, delivery kanban, etc. 1. Picking kanban is mainly located between processes in the workshop, mainly including sequence number, process name, process operator, blanking time, quantity, completion time, first inspection, etc. 2. Delivery status management kanban is mainly located in the production workshop, and its contents mainly include process sequence number, team name, product completion date, delivery date, receiving customer, etc. (6) Work-in-process kanban: including (1) work-in-process kanban; ② Signal kanban (record the types and quantities of parts and components that must be produced and ordered in the subsequent process). (2) Kanban collection: including (1) kanban between processes; (2) Kanban for external orders (record the types and quantities of parts and components that should be collected from the previous process in the subsequent process). Kanban function Kanban was originally created by Toyota Motor Corporation in 1950s, and was inspired by the operation mechanism of supermarkets as a transmission tool for production and delivery instructions. After nearly 50 years of development and improvement, it has played an important role in many aspects. Work order production and work order delivery are the most basic functions of Kanban. The production instructions made by the production management department of the company headquarters according to the market forecast and orders only reach the assembly line, and the production of each previous process is carried out according to Kanban. Kanban records the production and transportation quantity, time, destination, location, handling tools and other information, from the assembly process to the previous process one by one. Take off the kanban on the used parts on the assembly line so that you can get it in the last process. The previous process only produces the quantity taken away by these kanban boards, and "collection in the next process" and "timely and appropriate production" are realized through these kanban boards. In order to prevent the excessive production of kanban, kanban must be used according to the established application rules. One of the rules is: "You can't produce or transport without kanban." According to this law, if there is no kanban in each process, it will neither be produced nor transported; If the number of kanban is reduced, the output will be reduced accordingly. Because kanban only indicates the necessary quantity, using kanban can automatically prevent excessive production and transportation. Another application rule of visual management kanban is "Kanban can only be stored if it is pasted on the object" and "The previous process should be produced in the order of removing Kanban". According to this rule, the management personnel at the job site can see the priority of production at a glance, which is convenient for management. As long as you look at the information expressed by the board, you can know the operation progress of the next process, the capacity utilization rate, inventory and personnel allocation of this process. The improvement function of the improvement tool kanban is mainly realized by reducing the number of kanban. The reduction of kanban quantity means the reduction of WIP inventory between processes. If the inventory of WIP is high, even if the equipment breaks down and the number of defective products increases, it will not affect the production of the next process, so it is easy to cover up the problem. Under JIT production mode, the above problems can not be ignored by reducing the quantity to reduce the inventory of WIP. In this way, the improvement activities not only solved the problem, but also enhanced the "physique" of the production line. Kanban is pronounced kanban in Japanese, and its original meaning is a board for reading or a card for conveying production tasks. English is a visual board. Kanban is a special tool for post-pull production, so it is also called Kanban production. 3. Features of Kanban: (1) Kanban has formulated rules to tell online operators what steps should be taken when there are problems in production. Who should I apply for help? (2) Kanban system has good visibility. (3) Kanban is a plan fine-tuning and schedule control method driven by customer demand. Two points must be observed: (a) Only produce products that customers (post-process) need, and never exceed customer demand. (b) Only produce according to the customer's production instructions. Never organize your own production. 4. The role of Kanban: ① As an instruction for production and picking. 2. Control the inventory quantity. 3. Prevent material shortage from causing production suspension. 4. Prevent excessive/premature production. 5. Grasp the abnormal production schedule. 6. Simplify property management. 5. Kanban application rules: 1. Only the required materials and quantities can be obtained in post-treatment. 2. Only the pre-process can be produced according to the instructions of the production kanban. To supplement the things and quantity taken in the next process. (3) No kanban/production articles can't be taken. (4) All items must be accompanied by kanban. (5) All items must be qualified. (6) Minimize the number of kanban sheets and reduce inventory. (6) The prerequisite for implementing Kanban: (1) single-process production; (3) quick die change; (4) Standard operation. (7) Two basic kanban types: (1) production kanban: used to indicate the time when each production starts. (2) Picking Kanban: used to indicate the time when the next process arrives at the previous process: (1) Collect data; (2) Calculate the number of kanban; (3) Design a pull-type kanban; (4) Comprehensive training; (6) start the pull kanban; (6) supervision and maintenance; (7) continuous improvement; (9) The highest level of Kanban application is to realize the flow production mode without Kanban.