Kanban Made Simple: Demystifying and Applying Toyota's Legendary Manufacturing Process
Using Toyota as an example, this is a step-by-step guide to incorporating the ingenuity of the kanban system into any manufacturing environment.
TABLE OF CONTENTS Kanban Made Simple: Demystifying and Applying Toyota's Legendary Manufacturing Process
Chapter 7: Initial Startup and Common Pitfalls
Overview
Well, here we are. We have formed a team, sized the kanban, developed a design, and developed training. So what's left? Are we ready to start up our kanban? (Well, almost!) Before we go live, we need to take care of several items to ensure a successful implementation. We need to:
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Confirm the design is implemented
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Confirm training is complete
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Check the inventories
Once you have taken care of these items, you are ready to get on with the startup of the kanban. Therefore, our kanban process flow extends to include the startup and implementation step, as shown in Figure 7-1.
Figure 7-1: Modified Kanban Process Flow.
After you have started the kanban, then you need to watch for common pitfalls that disrupt the operation of the kanban. Consider these pitfalls as growing pains of your adolescent scheduling process. Therefore, as you identify problems, correct the problem and remember your role as a coach and mentor.
Confirm That the Design Is Implemented
Before you start the kanban, make sure that you have implemented the kanban design. To make sure you're ready, verify the following items:
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Are the kanban signals completed?
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Are the rules posted?
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Is the visual management information posted?
Don't make a half-hearted attempt at implementation. Make sure these items are complete. Make sure that everything is posted and looks as originally intended.
Having the design implemented simplifies the process of changing from the current scheduling system to the new kanban system. It also makes the training portion...
Copyright John M. Gross and Kenneth R. McInnis 2003 under license agreement with Books24x7
