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APPLICATION of KANBAN SYSTEM for IMPLEMENTING LEAN MANUFACTURING (A CASE STUDY) 1 2 3 B.Vijaya Ramnath, C

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APPLICATION of KANBAN SYSTEM for IMPLEMENTING LEAN MANUFACTURING (A CASE STUDY) 1 2 3 B.Vijaya Ramnath, C Journal of Engineering Research and Studies Research Article APPLICATION OF KANBAN SYSTEM FOR IMPLEMENTING LEAN MANUFACTURING (A CASE STUDY) 1 2 3 B.Vijaya Ramnath, C. Elanchezhian and R. Kesavan Address for Correspondence 1,2 Research Scholar, 3Asst. Professor, Department of Production Technology, Anna University, MIT Campus, Chennai-44, Tamilnadu Email: [email protected] ====================================================================== ABSTRACT This paper deals with implementation of lean manufacturing in Engine valve machining cell in a leading auto components manufacturing industry in the South India. The main objective of this paper is to provide a background on lean manufacturing, present an overview of manufacturing wastes and introduce the tools and techniques that are used to transform a company into a high performing lean enterprise. Value stream mapping is a main tool used to identify the opportunities for various lean techniques. The focus of the lean manufacturing approach is on cost reduction by eliminating Non- Value added activities. Applications have spanned many sectors including automotive, electronics and consumer products manufacturing. In this paper, Value Stream Mapping (VSM) is used to map the current operating state for production line. This map is used to identify sources of waste and to identify lean tools for reducing the waste. To eliminate the wastes found from the current state map Kanban system is suggested for pre machining section and single piece flow concept is suggested for machining section. Then a future state map has been developed for the system with lean tools applied to it KEYWORDS: Lean manufacturing, Value Stream Mapping and Kanban System 1. INTRODUCTION system focused on and driven by customers, Many manufacturers are now critically both internal and external. evaluating their processes to determine their The aim of Lean Manufacturing is the effectiveness in bringing maximum value to elimination of waste in every area of customers. Factory management techniques production including customer relations, of yesterday are being replaced by more product design, supplier networks, and efficient methods that greatly minimize factory management. Its goal is to delays, reduce costs, and improve quality. incorporate less human effort, less Lean manufacturing is a whole- systems inventory, less time to develop products, approach that creates a culture in which and less space to become highly responsive everyone in the organization continuously to customer demand while producing top improves processes and production. It is a quality products in the most efficient and JERS/Vol. I/Issue I/July-Sept. 2010/138-151 Journal of Engineering Research and Studies economical manner possible. of products. In accordance a leading valve Essentially, a "waste" is anything that the manufacturing unit in South India who are customer is not willing to pay for. Typically interested in implementing the lean the types of waste considered in a lean manufacturing concept. manufacturing system are Overproduction, 4. STUDY OF MANUFACTURING Waiting, Inventory or Work in Process METHODS AND SEQUENCE OF (WIP), Processing waste, Transportation, OPERATIONS Motion and Making defective products. The following sections show the processes 2. METHODOLOGY and sequence that have been currently done The following steps are involved in the in the company to bring the final product implementation of lean manufacturing. (Engine Valve) from the raw material which • Choosing a product or product family and is stored in the raw material store. Study of manufacturing methods and 5. CURRENT STATE FOR PASSENGER sequence of operations. CAR ENGINE VALVE MANUFACTURING • Study of layout and Construction of LINE Current State Value Stream Map. Data collection for the material flow started • Identification of Wastes and Looking out at the shipping department, and worked for the methods to eliminate these wastes. backward all the way to the upset and forging process, gathering snapshot data • Construction of Future State Value Stream such as inventory levels before each Map and Implementation of the proposed process, process cycle times (C/T), number concept. of workers, and changeover (C/O) times, • Analysis of economical benefits associated materials handling system etc., for the with proposed concept. current state mapping. The Value Stream 3. CHOOSING A PRODUCT OR Mapping for the passenger car engine PRODUCT FAMILY valve manufacturing line has been drawn. It would be highly creditable to implement By analyzing the Value Stream Mapping, the concept of lean manufacturing in an the following activities are found as the organization which has smaller more flexible wastes. machines that are typically organized into work cells devoted to production of a family JERS/Vol. I/Issue I/July-Sept. 2010/138-151 Journal of Engineering Research and Studies Fig 1: Present Manufacturing Line The operations, head diameter turning and grinding of valve seat is necessary, but grooving & chamfering have been done by before that the valve seat turning is not two consecutive machines. Two necessary as it have currently being done. consecutive grinding operations have been Therefore it is the waste process. The same done by two consecutive grinding end finishing operation has been done at machines. Two valve seat grinding two different stations. The semi finished machines have been used to meet the products in batches are moved manually customer demand. This is due to the between stations. This leads to excessive incorrect selection of grinding wheels. The transportation waiting of products. Loading JERS/Vol. I/Issue I/July-Sept. 2010/138-151 Journal of Engineering Research and Studies and unloading activities are done at each product. This above wastes indicates the station and therefore it needs one operator improvement opportunities from current at every station and it also leads to line. By going through these wastes, the operator fatigue. Most of the machines methods to eliminate or reduce these wastes have its own inspection stations even are to be found. Then the Future State Map though the inspection does not add value to be drawn considering with the improved to the products. Moreover the machining methods. Then the two maps are to be process is stopped when the inspection is analyzed to compare the economical done. The operators are idle, in most of the benefits Future state over current state. stations, while the machine process the Table 1 : Current State for Passenger Car Engine Valve Manufacturing Line Process Cycle Value Change NO. WIP Loading Unloading NO. of Method Time Added Over of m/c per of in sec Time Time in opera- operator Trans- in sec tor ferring sec Rough 13 11 600 1 200 Manual Auto 1 Manual grinding Head 18 15 300 1 0 Auto Auto 1 Manual diaturning Grooving 10 8 300 1 500 Auto Auto 1 Manual and chamfering Finish 5 3 300 1 1500 Auto Auto 1 Manual tappet end I Intermediate 14 11 900 1 1500 Manual Auto 1 Manual grinding Finish 14 12 900 1 0 Manu Auto 1 Manual grinding al Flame 15 13 0 1 1000 Manual Manual 1 Manual Hardening JERS/Vol. I/Issue I/July-Sept. 2010/138-151 Journal of Engineering Research and Studies Seat 14 11 300 1 1000 Auto Auto 2 Manual grinding Finish 5 3 300 1 1000 Manual Auto 1 Manual ta ppet 6. ELIMINATION OF WASTES BY 6.4 Functions of Kanban system PROCESS IMPROVEMENTS • It provides pick up or transport information. 6.1 Kanban System for Pre Machining • It provides production information. Section • It prevents over production and excessive 6.2 Introduction to Kanban System transport. The word Kanban has come to stand for a • It serves as a work order attached to goods. variety of items ranging from shelves, bins, • It reveals existing problems and maintains electronic messages and order slips to the inventory control. entire reorder point system. It is a small 6.5 Criteria to select Kanban items piece of a large puzzle. Kanban system • Self certified items, that are past 6 months guides everyone in an industry from machine there is no quality issue. operator to trolley driver to know what the • For stable process. next process to be carried out 6.3 Kanban Technique • For tools life monitoring system The technique that makes the JIT principles • Once in 3 months raw material inspection practical is called KANBAN. KANBAN is report must be submitted. a Japanese word meaning signboard or • Once in 3 months layout inspection report billboard. (Kan = visual, Ban = card). must be submitted. Kanban is a signal to replace what has been • Any process change must be approved by used. If the authorization is present, one can customer. act. If it is not one can’t. KANBAN is • Special process must be approved by customer. therefore a way of controlling inventory. In earlier days Kanban is the special 6.6 Kanban flow diagram manufacturing system proposed by Toyota JERS/Vol. I/Issue I/July-Sept. 2010/138-151 Journal of Engineering Research and Studies 6.7 Types of Kanban Unnecessary inventory is very important as The kanban system is based on use of cards it affects more, the cost of production. We called ‘Kanbans’. The card is put in a can call this production as a ‘Push rectangular vinyl slack. The following three Production’ as the machine stations in the kinds of cards are normally used: manufacturing line produces the valves based • Move kanban on the capacity of the machine station not based on the demand. And also a WIP of 3 • Production kanban days of demand are maintained along the • Supplier kanban manufacturing line. Kanban system is an To make kanban system work, manufacturing information system to harmoniously control processes are designated as preceding process the production quantities in every process. and subsequent process. The withdrawal We have suggested that this Kanban system kanban details the quantity that the can be implemented to reduce the inventory subsequent process should withdraw, while in the pre-machining section (Raw material, the production ordering kanban shows the Upsetting & forging and Heat treatment).
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