Kanban Made Simple: Demystifying and Applying Toyota's Legendary Manufacturing Process PDF
Preview Kanban Made Simple: Demystifying and Applying Toyota's Legendary Manufacturing Process
Kanban Made Simple ..........................9896$$ $$FM 02-20-0309:27:10 PS This Page Intentionally Left Blank ..........................9896$$ $$FM 02-20-0309:27:10 PS Kanban Made Simple Demystifying and Applying Toyota’s Legendary Manufacturing Process John M. Gross Kenneth R. McInnis American Management Association NewYork•Atlanta•Brussels•BuenosAires•Chicago•London•MexicoCity SanFrancisco•Shanghai•Tokyo•Toronto•Washington,D.C. ..........................9896$$ $$FM 02-20-0309:27:11 PS SpecialdiscountsonbulkquantitiesofAMACOMbooksareavailabletocorporations, professionalassociations,andotherorganizations.Fordetails,contactSpecialSales Department,AMACOM,adivisionofAmericanManagementAssociation 1601Broadway,NewYork,NY10019. Tel.:212-903-8316.Fax:212-903-8083. Website:www.amacombooks.org This publication is designed to provide accurate and authoritative information in regard to thesubjectmattercovered.Itissoldwiththeunderstandingthatthepublisherisnotengaged in rendering legal, accounting, or other professional service. If legal advice or other expert assistanceisrequired,theservicesofacompetentprofessionalpersonshouldbesought. Althoughthispublicationissubjecttocopyright,permissionisgrantedfreeofchargetouse andprintpagesfromtheenclosedCD-ROM.Onlytheoriginalpurchasermaymakecopies. Under no circumstances is permission granted to sell or distribute on a commercial basis materialreproducedfromthispublication. LibraryofCongressCataloging-in-PublicationData Gross,JohnM. Kanbanmadesimple:demystifyingandapplyingToyota’slegendary manufacturingprocess/JohnM.Gross,KennethR.McInnis. p. cm. Includesbibliographicalreferencesandindex. ISBN0-8144-0763-3 1.Just-in-timesystems. 2.Productioncontrol. 3.Factory management. I.McInnis,KennethR. II.Title. TS157.G74 2003 658.5—dc21 2002154533 (cid:2)2003JohnM.GrossandKennethR.McInnis. Allrightsreserved. PrintedintheUnitedStatesofAmerica. Thispublicationmaynotbereproduced,storedinaretrievalsystem,ortransmittedinwhole orinpart,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,or otherwise,withoutthepriorwrittenpermissionofAMACOM,adivisionofAmerican ManagementAssociation,1601Broadway,NewYork,NY10019. Printingnumber 10 9 8 7 6 5 4 3 2 1 ..........................9896$$ $$FM 02-20-0309:27:12 PS C ONTENTS Preface vii Chapter1 IntroductiontoKanban 1 Chapter2 FormingYourKanbanTeam 19 Chapter3 ConductDataCollection 32 Chapter4 SizetheKanban 48 Chapter5 DevelopingaKanbanDesign 86 Chapter6 Training 124 Chapter7 InitialStartupandCommonPitfalls 137 Chapter8 AuditingtheKanban 148 Chapter9 ImprovingtheKanban 158 Chapter10 Conclusion 178 Appendixes AppendixA MRPvs.Kanban 181 AppendixB KanbanSupermarkets 185 AppendixC Two-BinKanbanSystems 189 AppendixD OrganizationalChangesRequiredforKanban 197 AppendixE EOQvs.Kanban 203 AppendixF ImplementationinLargePlants 215 AppendixG Intra-CellKanban 219 v ..........................9896$$ CNTS 02-20-0309:27:33 PS vi CONTENTS AppendixH CaseStudy1:MotorPlant—CastingKanban 223 AppendixI CaseStudy2:RubberExtrusionPlant 233 AppendixJ Acronyms 247 Index 249 About theAuthors 259 ..........................9896$$ CNTS 02-20-0309:27:33 PS P REFACE Wedecidedtowritethisbookwhiletravelingtogetheronabusiness trip.Returning fromameeting withasupplier whomwe wantedto place on kanban scheduling, we were discussing how resistant the supplierhadbeentotheidea.Ourdiscussionmigratedtohowmost companiesandindividualswereresistantatfirst,butthattheysoon came on board once they understood the benefits of using kanban. We discussed how this resistance stemmed from lack of exposure andthelackofbooksabouthowactuallytodevelopandimplement kanban scheduling. Twenty miles later we were building what be- camethefourteen-pageoutline forthisbook. The Best Way to Read this Book To get the most out of this book, we recommend reading this book inthreepasses. ❑ On your first pass, flip through the entire book and look at all of the chapters, look at its organization, and look at the figures. Getacquaintedwiththestyleandflow. ❑ On the second pass, read the book chapter by chapter. At thestartofeachchapter,conductanotherquickreviewofthechap- ter.Duringthisreview,flipthroughthechapterlookingatthemajor topics and figures. Finish this review by reading the chapter sum- mary. ❑ On the final pass, go back to the beginning of the chapter vii ..........................9896$$ PREF 02-20-0309:27:47 PS viii PREFACE andreadtheentirechapter.Duringthisfinalpass,lookforthedetail behind the topics in the chapter summary. Also, make notes and underline importantinformationinthemargins. Although this process sounds like it might take forever and slow down your reading, the opposite is true. The three-pass proc- ess will not only improve comprehension, but also speed up your reading. Acknowledgments We wish to thank the following people for their support in making thisbookareality:Sharon Leedevelopedtheauditformspresented in Chapter 8; Loyd Bailie, Sharon Lee, Charles McInnis, and Ron Fardellreadthedraftsassanitychecksonourlogic;DeanKropp,of WashingtonUniversity–St. Louis,providedideasandsupport. We wish to thank the companies that allowed us to document theirkanbansuccessesinthecasestudies.Wewouldespeciallylike to thank GDX Automotive for allowing us not only to document a casestudy,butalsototakepicturestoillustratesomeofthekanban designsinChapter5.Theirthree-phasedLeanimplementationpro- gram, called Common Sense Manufacturing, is making dramatic stridesinwasteelimination. We also would like to thank our wives, Karen Gross and Ruth McInnis, for their support during the writing and editing of the book. Theirsupport allowed usto write thebook andstill maintain our hecticprofessionalschedules. Finally, we wish to thank you for taking the time to read this book. We hope it gives you the knowledge (and the courage) to implement kanban scheduling in your operation. We know from first-hand experience that the improvement in flow, the benefits of empowering the production operators, and inventory reductions willamazeyou. JohnM.Gross KennethR.McInnis ..........................9896$$ PREF 02-20-0309:27:47 PS Other Works by the Authors JohnM.Gross,FundamentalsofPreventiveMaintenance, AMACOM,2002. ..........................9896$$ WRKS 02-20-0309:28:02 PS
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