JUST IN TIME

CHNG 2 HE THONG KANBAN TRONG JIT

Noi dung

Gii thieu ve Kanban Khai niem ve Kaban Vai tro cua Kaban Cac loai Kaban Cac nguyen tac cua Kaban u nhc iem cua Kaban

V du ve Dong thong tin trong he thong ay

V du ve Dong thong tin trong he thong Keo

Gii thieu ve Kanban

oi hoi au tien oi vi san xuat JIT la tat ca cac qua trnh can phai biet chnh xac thi gian va so lng san xuat yeu cau. Khi ke hoach thay oi hoac gap s co, phng phap san xuat truyen thong oi hoi phai d tr/ ton kho qua nhieu lang ph. Trong He thong keo: cong oan sau lay ban thanh pham, chi tiet cua cong oan trc va cong oan trc ch san xuat ung so lng va thi gian ma cong oan sau yeu cau Ke hoach ieu chnh phai c thong bao ay u va kp thi cho cac bo phan trong cong ty
trnh biet thi gian, so lng san xuat cua tat ca cac bo phan
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S dung KANBAN e thong tin cho tat ca cac quy

Logic Nhu cau Keo trong Kanban

Here the customer starts the process, pulling an inventory item from Final Assembly Then sub-assembly work is pulled forward by that demand

Fab
Sub Fab Fab Sub Fab

Vendor

Customers

Final Assembly

Vendor Vendor

The process continues throughout the entire production process and supply chain

Vendor
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Toi thieu Lang ph: He thong kiem soat san xuat theo Kanban
Once the Production kanban is received, the Machine Center produces a unit to replace the one taken by the Assembly Line people in the first place

Withdrawal kanban

This puts the system back were it was before the item was pulled

Machine Center

Storage Part A

Storage Part A

Assembly Line

Production kanban
The process begins by the Assembly Line people pulling Part A from Storage

Material Flow
Card (signal) Flow
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Khai niem Kanban

Kanban c phat minh Nhat. Trong tieng Nhat, Kan co ngha la the (card) va Ban co ngha la tn hieu (signal). Thc te Kanban co the la the, c, hop rong, khoang trong tren ke/ tu. v.v Kanban la he thong san xuat KEO giup kiem soat dong cong viec trong suot nha may bang cach ch a vat t vao san xuat khi co nhu cau khach hang, ngha la khi chung c can en. Kanban kiem soat ton kho tren nen tang JIT. He thong ay, ngc lai, se a vat t vao san xuat khi cac n at hang c xem xet va vat t a san sang. Kanban la mot he thong giup kiem soat qua trnh san xuat. The Kanban bao gom cac thong tin ve tai at hang va c xoay vong gia khach hang va nha 8 cung cap

Khai niem Kanban (tt)

Kanban cho phep trao quyen san xuat theo dong t di len (t khach hang) Keo vat t xuyen qua nha may
Thng s dung vi thung cha co kch thc co nh Them hoac di chuyen thung cha e thay oi mc o san xuat
Tren the KANBAN co mot so thong tin can thiet sau ay:

Loai chi tiet, san pham ang c san xuat. Sc cha cua container/bao/thung/hop. a ch, ky hieu cua ni lam viec quy trnh trc. a ch, ky hieu cua ni lam viec quy trnh sau.
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Ap dung he thong KANBAN can xac nh lng the KANBAN trong lu chuyen

Kanban
He thong keo: - Giam ton kho - Tang tnh linh hoat e ap ng nhu cau khach hang (giam lead times) - Giup at ti s ong bo trong cng o cong viec cua he thong van hanh - Tao bang chng ngay cho cac van e

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V du: The Kanban

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Vai tro cua the Kanban

Hng dan: Kanban a ra cac lenh san xuat (so lng)/ van chuyen ti ni nao? T kiem tra: Kanban giup ngan nga san xuat tha, ch san xuat tai thi iem phu hp Kiem tra trc quan: Kanban cung cap thong tin khong ch qua so lieu ma con qua cac bieu hien vat ly (mau sac, hnh dang) Cai tien hoat ong cua qua trnh: Kanban giup cai tien san xuat cai tien ve mat tai chnh, nang cao hieu qua hoat ong cho doanh nghiep Giam chi ph quan ly: do Kanban khong can en cong tac ieu o giam nhan lc
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Xac nh so the Kanbans can thiet

Xay dng he thong Kanban can xac nh c so the Kanban can thiet Moi the ai dien cho qui mo toi thieu cua mot lo san xuat Viec c lng chnh xac lead time yeu cau e san xuat mot kien hang la yeu to chnh e xac nh Bao nhieu Kanban la can thiet

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V du: Xac nh so Kanban

Expected demand during lead time Safety stock k Size of the container dL(1 S ) C
k = Number of Kanban card sets (equivalent to number of bins for this part) d = Average number of units demanded over some time period L = lead time to replenish an order (same units of time as demand) S = Safety stock expressed as a percentage of demand during lead time C = Container size

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V D

Cong ty c moi mot gi can phai giao cho khach hang150 san pham A va phai san xuat trong 05 gi lien tuc. Cong ty uc tnh lng gi tr an toan la 10%. San pham A khi giao cho khach hang c ong vao thung, moi thung cha 10 n v. Hay tnh so the Kanban can co e ap ng n hang tren? d = 150 sp/h. L = 05hrs. S = 0.1 C = 10sf/th So the k = 150x5x(1+0.1)/10 ~ 83 the

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Phan loai Kanban

Co 2 loai chnh
KANBAN san xuat : ghi ro lng san pham ma qua trnh trc phai san xuat.
Store
Shelf No F26 18 Item Bach No A5 - 34 Process

Item No 56790 321

Item Name CRANK SHAFT Car Type SX50BC 150

MACHINING
SB - 8

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Phan loai Kanban

KANBAN thu hoi : ghi ro loai, lng san pham qua trnh sau phai thu hoi (rut ra hoac nhan) t qua trnh trc.

Store Shelf No F26 18 Item Bach No A5 - 34 Item No 56790 321 Item Name CRANK SHAFT Car Type SX50BC - 150 Box Capacity Box Type 20 B Issue No 4/8 M-6 Preceding Process FORGING B-2 Subsequent Process MACHINING

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Phan loai Kanban

Mot so loai khac Kan ban toc hanh: c s dung khi co s thieu hut cac chi tiet/ ban thanh pham cho qua trnh sau ton tai song song vi KANBAN san xuat va KANBAN thu hoi, ch c dung trong tnh huong ac biet, phai thu lai ngay sau khi tien trnh dien ra bnh thng Cac bc thc hien:

Neu ngi cong nhan s dung KANBAN toc hanh oi

vi chi tiet B a KANBAN o vao tram KANBAN toc hanh (con goi la tram o) ben canh tram ng KANBAN san xuat cua qua trnh che tao. Cung luc, ngi cong nhan nhan nut bao hieu cho day chuyen e san xuat chi tiet B. Nut bao hieu nay c lap ben canh tram cha KANBAN san xuat.

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Kanban toc hanh (tt)

Tren bang en hieu, mot en tng ng vi chi tiet B se hoat ong, ch nh viec san xuat chi tiet B. Tren day chuyen san xuat en nay phat tn hieu, ngay lap tc ngi cong nhan phai san xuat chi tiet B va mang no en day chuyen lap rap sau. Khi ap ng yeu cau dng Kanban cho san pham B va tiep tuc san xuat bnh thng nh trc o.
From To Withdrawal KANBAN
Store No. 3 Plant Item No 3D315 55780E04 Crank Shaft Box capacity 15 1/20 Bach No A2 214

Item Name
Type Car PX406BC - 110

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Phan loai Kanban

Kanban

c s dung tam thi khi co nhu cau bu ap cho lng phe pham do truc trac may moc. KANBAN nay c coi nh bien dang cua KANBAN thu hoi hay KANBAN san xuat, va phai c thu hoi ngay sau khi s dung.
Production ordering KANBAN
Store Item No Item Name Car Type Container Capacity Issued No Back No

khan cap:

Process

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Cach s dung Kanban

Co tam bc c ban:
Ngi van chuyen qua trnh sau i en tram A cua qua trnh trc vi nhng the KANBAN thu hoi at trong hop ng KANBAN va nhng thung cha rong at tren xe ay. Khi ngi van chuyen nay lay i mot so chi tiet trong thung cha tram A, anh ta phai g the KANBAN san xuat c at trong cac thung cha ra (moi thung cha co 1 Kanban) va at nhng KANBAN san xuat nay vao hop nhan KANBAN. Sau o, anh ta at thung cha rong vao cho qui nh cua qua trnh trc Vi moi KANBAN san xuat c rut ra, anh ta phai thay vao o Kanban thu hoi. Khi trao oi hai the KANBAN nay anh ta phai so sanh can than KANBAN thu hoi vi KANBAN san xuat sao cho trung khp. Khi qua trnh sau bat au lam viec, nhng KANBAN thu hoi phai c tach ra khoi hop chi tiet va c at trong thung cha KANBAN thu hoi.
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Cach s dung Kanban

5.

qua trnh trc, nhng Kanban san xuat se c thu thap t hop cha KANBAN tai mot thi iem nhat nh hoac khi mot so lng nhat nh c che tao, va phai c at trong hop ng Kanban san xuat theo ung th t ma no a c thao ra Tram A. Che tao cac chi tiet theo th t cua KANBAN san xuat trong hop ng Kanban. Nhng chi tiet che tao va the KANBAN luon phai di chuyen theo tng cap doc theo tien trnh san xuat

6.

7.

8.

Khi nhng chi tiet c hoan thanh, cac chi tiet nay va Kanban san xuat c at lai vao tram A, tai o ngi van chuyen qua trnh sau co the rut chung ra bat ky thi iem nao.
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Cac bc s dung Kanban

Production ordering Kanban post Kanban recerving post 5 2 Production ordering Kanban 3 Withdrawal kanban and physical units

7 8 6 Preceding process (machinery line)

Store A

4
Withdrawal Kanban Withdrawal Kanban post 1 Subsequent process (assembly line)

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Cac nguyen tac cua Kanban

Nguyen tac 1:

Qua trnh sau lay ra mot so loai san pham can thiet t qua trnh trc vi so lng can thiet tai thi iem can thiet.
Cac nguyen tac phu: Khi lay bat mot chi tiet hay hang hoa th phai co KANBAN. Hang hoa lay ra khong c nhieu hn so KANBAN. Moi thung cha san pham eu c gan KANBAN. Nen chu y nhng ieu kien tien quyet cua KANBAN: can bang san xuat, ngng san xuat va tieu chuan hoa cong viec.
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Cac nguyen tac cua Kanban

Nguyen tac 2:

Qua trnh trc phai san xuat bang so lng ma qua trnh sau a lay.
Cac nguyen tac phu: Khong c san xuat nhieu hn so lng KANBAN yeu cau. Neu qua trnh trc san xuat nhieu loai chi tiet khac nhau th viec san xuat phai theo cac chuoi ban au ma KANBAN a ghi. Qua trnh sau oi hoi tng n v san pham rieng le hoac lo nho e at c san xuat lien tuc qua trnh trc phai c sap at e ap ng nhanh nhng yeu cau cua qua trnh sau
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Cac nguyen tac cua Kanban

Nguyen tac 3:

Nhng san pham b loi khong c chuyen en quy trnh sau.

He thong KANBAN se b pha huy neu khong tuan theo nguyen tac 3. Neu qua trnh sau phat hien nhng san pham loi th day chuyen phai ngng lai (do khong co ton kho)
Loi thng gap la loi ve van hanh may moc, do cha at c tieu chuan hoa (van hanh bang tay, thoi quen va gi lao ong, v.v) tieu chuan hoa cong viec la mot ieu kien tien quyet cua he thong KANBAN.

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Cac nguyen tac cua Kanban

Nguyen tac 4:

Giam thieu lng KANBAN.

Neu cai tien qua trnh san xuat bang viec giam c lo san xuat va rut ngan thi gian san xuat so lng KANBAN can thiet co the giam Khi nhu cau hang ngay tang len oi hoi giam thi gian chu ky san xuat can phat huy vai tro cua cong nhan trong day chuyen hp ly va hieu qua. Tuy nhien, do so lng KANBAN co nh, tram cong viec nao khong co kha nang cai tien nh yeu cau tren se b nh tre va buoc phai san xuat ngoai gi. Neu nhu cau tang len qua nhieu co the tang so lng KANBAN. Neu nhu cau giam xuong chu ky cua qua trnh se tang len co the giam lng cong nhan d tha tren day chuyen e tranh thai o l la cua ho.
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Cac nguyen tac cua Kanban

Nguyen tac 5:
KANBAN c s dung e ieu chnh oi vi s thay oi nho trong nhu cau.

ieu chnh san xuat nh vao kha nang ap ng c s thay oi bat ng cua nhu cau hoac trnh trang khan cap trong san xuat cua KANBAN Ni KANBAN c s dung va san xuat c can bang se de dang ap ng nhng thay oi tren th trng nh vao viec san xuat nhieu hn nhng lng nho theo nhu cau.
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Cac nguyen tac cua Kanban

Nguyen tac 6:

So lng cac bo phan thc te cha trong hop hoac ong trong goi phai bang vi so lng viet tren KANBAN.

KANBAN at vao hop bo phan phai c lay ra va at hop thu nhan khi n v au tien c s dung. Nhng the KANBAN nay phai c thu lai thng xuyen va chuyen ti qua trnh trc. Viec van chuyen nay c lam hang gi. Mc can bang san xuat qua trnh cuoi la quan trong so lng bo phan lay i t qua trnh trc phai c can bang lai. Neu cong viec can phai lam ngoai gi e cung cap san pham them nhng KANBAN cap toc (Express KANBAN) phai c cap vi so lng nho va thu ve mot cach nhanh chong khi viec san xuat them hoan tat.
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ieu kien ap dung he thong Kanban

Viec s dung KANBAN oi hoi phai co mot he thong thong tin ro rang co kha nang the hien tat ca nhng van e cua qua trnh san xuat. Quan ly dong san pham bi KANBAN oi hoi dong san xuat phai linh hoat, thong suot. Neu khong giai quyet cac roi loan trong san xuat, he thong KANBAN co xu hng khuyech ai hau qua lam cho mc d tr tang len. Nhng van e cua he thong san xuat can phai c giai quyet trc khi ap dung phng phap KANBAN, va can phai c tiep tuc ca sau khi a ap dung he thong KANBAN.

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ieu kien ap dung he thong Kanban

Nhng s thay oi can thiet cua he thong san xuat: Bo tr hp ly thiet b may moc cac xng.

Thi gian hieu chnh cac thay oi cua san pham ngan. Loai bo cac bien ong ngau nhien. Phat trien, cung co moi quan he chat che vi nha cung cap. Ngi lao ong can co tnh a nang cao, co kha nang luan phien cong viec, kha nang ieu chnh va bao dng may moc khi can thiet. Tieu chuan hoa cac bo phan, cac n v lap rap san pham giam c so lng danh muc quan ly, giam so lan thay oi loat gia cong va giam so loai KANBAN.

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u Nhc iem cua Kanban

u iem:

Cho phep thay c nhng van e can c giai quyet cua xng. Thc hien he thong kiem soat khong can ien toan hoa (ien toan hoa de tao nen cac ph ton to ln) Lu chuyen nhanh thong tin gia cac ni lam viec, lien quan en tnh hnh lam viec cua may moc thiet b, hong hoc phat sinh, phe pham v.v

Phoi hp an y gia cac bo phan do chung b phu thuoc vao nhau.

Thch ng tot gia qua trnh san xuat vi s thay oi nho cua nhu cau (t 10-12%)
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u iem (tt)

Hoan thien phng thc phuc vu khach hang do thi gian thoa man yeu cau cua khach hang ngan v san xuat theo nhng lo nho va thng xuyen Phan quyen quan ly c ap dung trc tiep trong cac phan xng san xuat. Ton kho thap nhat Khong can lap ke hoach hang ngay. Kiem tra san xuat bang KANBAN la then chot (ben canh nhng he thong khac nh Andon, kiem tra bang mat thng v.v) Hieu chnh chnh xac ke hoach theo MRP II, ket hp gia ke hoach san xuat dai han va san xuat ngan han.
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Nhc iem

Khong ap ng c khi co s dao ong ln ve nhu cau do ap dung he thong keo, khong co ton kho Toan bo he thong b anh hng khi co mot s roi loan trong san xuat cua bat ky cong oan nao

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Q&A

Tai sao he thong san xuat JIT can ap dung Kanban? Trnh bay cach tnh so Kanban

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